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The manual service (this one piece was given to me by Suzuki repretsentative) only describes how the maximum amount of flatness to be corrected: 0,05mm!
I think this is a misinterpretation - the service manual does not say that 0.05mm is the maximum amount of distortion that can be corrected, but rather that distortion that exceeds 0.05mm needs to be corrected.
I agree that you cannot remove material willy-nilly from the deck, if you do you run the risk of the piston crowns being higher than the deck with potentially disastrous (piston/head/valve contact) results, which don't seem to have happened here, the other possible effects are the cam timing being retarded (overhead cam engines only), which is fairly easy to check and an increase in compression ratio, which would/should show in the compression numbers, which we have been told are "ok".
Last edit: 05 Sep 2026 01:28 by fordem. Reason: reword for clarity
Excessive fuel use and low power with spluttering running is very often associated with the primary catalytic converter having failed and the debris from that then blocking the secondary converter. If the symptoms only started after the engine was removed for the machining work it's entirely possible that taking it out disturbed the exhaust and hastened the demise of the catalytic element. It sounds coincidental to me, I'd not expect mating surface machining to cause your jimny to not run properly.
In fact, the engine was removed after an overheating failure with engine stalled. This shouldn't have happened, as the vehicle had recently undergone a major service, including the cooling system. Unfortunately, the engine was sent to the repair shop without prior testing of the sensors, and after reassembly, the scanner indicated and we replaced many sensors, including the pre- and post-cat. The catalytic converter itself was not serviced. After that, I went do a Suzuki oficial workshop that told me about the excess of flatness correction as a possible cause.
In fact, the engine was removed after an overheating failure with engine stalled.
I'm going to assume that this translates into the engine overheated & seized. In a situation like this, it would not be normal to check any sensors, if the engine has seized, it's a mechanical problem.
What was it the scanner indicated after reassembly and what sensors were replaced & why?
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