2002–2003 Honda Civic Si / SiR (Canada) Factory Service Manual (P/N 08718-0009)

• Covers 2002–2003 Honda Civic Si (U.S.) and SiR (Canada) EP3 2-door Hatchback models with the K20A3 2.0L DOHC VTEC engine and NRH3 5-speed manual transmission, including side-airbag-equipped model grades.
• Covers engine removal and installation, cylinder-head service, VTEC rocker-arm and VTC actuator testing, cam-chain service, valve adjustment, crankshaft and piston work, bearing selection, cylinder honing, and oil-pump repair.
• Includes clutch hydraulic service and bleeding, clutch and flywheel inspection, transmission removal, internal disassembly and reassembly, mainshaft/countershaft work, synchro inspection, differential adjustment, driveshaft service, and intermediate-shaft repair.
• Provides PGM-FI/ECM diagnostics, DTC and freeze-data troubleshooting, fuel-pump and EVAP testing, idle-learn procedures, plus starting, ignition, charging, and cruise-control circuit diagnosis.
• Covers EPS steering diagnosis and gearbox overhaul, wheel alignment, hub and bearing replacement, front and rear suspension work, conventional brake repair, ABS DTC troubleshooting, brake bleeding, and ABS modulator service.
• Includes HVAC diagnosis and refrigerant service, body and interior procedures, multiplex-related electrical troubleshooting, SRS diagnosis, factory circuit diagrams, exploded views, service-limit tables, torque data, and Honda special-tool references. The publication identifies itself as First Edition 8/2002, 1,168 pages, with specifications for U.S.A. and Canada.

Engine, Drivetrain, and Electrical Systems

This Honda service manual is built around the EP3 Civic configuration rather than the broader Civic engine and transmission combinations used in other chassis. The identification section decodes the EP3 as the Civic/K20A3 platform and identifies the NRH3 5-speed manual transmission, with separate 2002 and 2003 chassis, engine, transmission, paint-code, and emission-label information.

Engine coverage goes well beyond routine maintenance. The cylinder-head section includes compression inspection, VTEC rocker-arm testing with dedicated air adapters, VTC actuator inspection, valve-clearance adjustment, cam-chain removal and installation, cylinder-head removal, camshaft and rocker-arm inspection, valve-guide replacement, valve-seat reconditioning, and cylinder-head installation. The block section continues into crankshaft and connecting-rod bearing selection, crankshaft inspection, piston and bore inspection, cylinder honing, piston-ring service, and in-car transmission-end crankshaft seal installation.

The drivetrain chapters are equally detailed. Clutch coverage includes pedal and switch adjustment, master and slave cylinder replacement, hydraulic bleeding, pressure-plate and clutch-disc inspection, flywheel inspection, and clutch replacement. The manual transmission section covers removal and installation followed by clutch-housing and transmission-housing exploded views, internal disassembly, shift-fork clearance checks, mainshaft and countershaft disassembly and inspection, synchro sleeve/hub and synchro-ring inspection, bearing and oil-seal replacement, transmission reassembly, differential backlash inspection, carrier-bearing replacement, and differential thrust-clearance adjustment. Driveshaft and intermediate-shaft inspection, disassembly, reassembly, and installation are handled in a separate driveline section.

Diagnostics, Chassis, and Factory Repair Data

Electrical diagnosis is organized around component-location indexes, circuit diagrams, connector testing, and fault-isolation procedures. Starting-system coverage includes starter circuit troubleshooting, clutch-interlock and solenoid testing, starter performance testing, replacement, and overhaul. Charging-system procedures cover alternator/regulator circuit diagnosis, alternator control testing, auto-tensioner inspection, and alternator overhaul. Fuel and emissions chapters add Honda PGM Tester/OBD II diagnostics, ECM circuit testing, fuel-pump troubleshooting, fuel-pressure diagnosis, injector and sensor testing, VTEC-related DTC work, EVAP leak diagnosis, and the ECM idle-learn procedure required after certain electrical or control-module work.

Representative electrical documentation includes the Starting System Circuit Diagram, Ignition System Circuit Diagram, Charging System Circuit Diagram, Cruise Control Circuit Diagram, ABS Circuit Diagram, and HVAC Circuit Diagram. These are backed by connector views, component-location drawings, DTC indexes, symptom charts, and system-specific test procedures rather than stand-alone wiring illustrations.

Chassis repair includes EPS power-assist diagnosis, steering-column service, rack-guide adjustment, steering gearbox removal and overhaul, front and rear suspension service, wheel-bearing and hub replacement, wheel alignment, brake-disc inspection, caliper overhaul, master-cylinder and booster work, brake-system bleeding, and ABS wheel-sensor and modulator diagnosis. HVAC coverage extends through control-motor testing, evaporator and heater-core replacement, compressor-clutch overhaul, refrigerant recovery, evacuation, charging, leak testing, and system performance tests. SRS material includes DTC and indicator-circuit troubleshooting, deployment-related inspection, airbag and sensor replacement, and dedicated SRS simulator tooling.

Honda special tools are identified by part number where required. Examples include the EOS02C000011 front subframe adapter, 07ZAJ-PNAA100 VTEC air adapter, 07VAE-001010A valve spring compressor attachment, 07JAF-PM7011A clutch alignment disc, and transmission, bearing, seal, hub, and ball-joint service tools throughout the relevant sections.

Several factory cautions show why the repair-specific procedures matter. During transmission mainshaft disassembly, Honda warns that an incorrect jaw-type puller can damage the gear teeth. The intermediate shaft must also be handled in the specified orientation during removal and installation to avoid damaging the differential oil seal. During engine installation, the mount hardware has a defined tightening sequence; ignoring it can produce excessive noise and vibration and shorten mount-bushing life.

Normal and severe-condition maintenance schedules are both included, with Canadian operation specifically addressed in the severe-service guidance. Follow the manual's safety precautions for fuel pressure, electrical isolation, brake work, refrigerant service, lifting, and SRS components before beginning repair work. The PDF gives experienced owners and repair shops the factory procedures, inspection criteria, special-tool information, and diagnostic structure needed to work on the covered EP3 configuration.