Honda Civic Si / SiR 2002–2003 Factory Service Manual (P/N 61S5T01)

Honda’s First Edition 8/2002 factory service manual, P/N 61S5T01, covers 2002–2003 Civic Si (U.S.) and SiR (Canada) EP3 hatchback models, including side-airbag-equipped grades. It addresses the K20A3 engine and NRH3 manual transmission, with model-year identification information for chassis numbers, paint codes, and emissions labels.

PDF Search, Wiring Detail, and Page Count

Search and diagram detail: Text search works across much of the manual, but some repair pages and diagram labels are not searchable. There are no embedded PDF bookmarks. Small wiring labels require zooming, and some fine diagram lines are faint.

The printable, English-language download contains 1,139 pages in one 27.57 MB PDF, including one cover page, one introduction page, and a seven-page index.

K20A3 Engine Repair and EP3 System Diagnosis

The selected coverage below outlines major workshop areas. Other included topics range from moonroof limit-switch adjustment to fuel-gauge sending-unit testing.

• Engine repair: Engine removal and installation, cylinder-head service, VTEC rocker-arm and VTC actuator testing, cam-chain work, valve adjustment, crankshaft and piston service, and oil-pump overhaul.

• Clutch and drivetrain: Hydraulic service and bleeding, clutch and flywheel inspection, transmission removal and internal overhaul, synchro inspection, differential adjustment, and driveshaft and intermediate-shaft repair.

• PGM-FI diagnostics: ECM troubleshooting, DTC and freeze-data diagnosis, fuel-pump and EVAP testing, injector and sensor checks, and idle-learn procedures.

• Electrical systems: Starting, ignition, charging, and cruise-control circuit diagnosis, with wiring diagrams, connector tests, component-location indexes, and multiplex troubleshooting.

• Steering, suspension, and brakes: EPS diagnosis and steering gearbox overhaul, wheel alignment, hub and bearing replacement, suspension service, conventional brake repair, ABS troubleshooting, and bleeding.

• Cooling and HVAC: Cooling-system pressure tests, thermostat and water-pump service, radiator and fan diagnosis, HVAC troubleshooting, refrigerant service, and compressor-clutch overhaul.

• Body and restraints: Door, glass, and interior procedures, SRS diagnosis, deployment-related inspection, airbag and impact-sensor replacement, and OPDS initialization.

Suited to repair shops and experienced owners who are comfortable with precision measurements and have access to the specified diagnostic equipment and Honda special tools.

Engine Inspection and Maintenance

Cylinder head: Step-by-step procedures cover camshaft and rocker-arm inspection, valve-guide replacement, valve-seat reconditioning, and cylinder-head installation. The VTEC rocker-arm test uses dedicated air adapters.

Block and lubrication: Crankshaft and connecting-rod bearing selection accompanies piston and bore inspection, cylinder honing, piston-ring replacement, and in-car transmission-end crankshaft seal installation. Oil-pump coverage includes rotor clearances and balancer-shaft inspection.

The engine-installation section specifies a mount-tightening sequence because errors can cause excessive noise and vibration and shorten mount-bushing life.

Maintenance and cooling: Normal and severe-condition schedules are included, with Canadian operation specifically addressed in the severe-service guidance. Radiator-cap testing, cooling-system pressure checks, thermostat inspection, and fan-circuit troubleshooting support cooling-fault diagnosis.

Clutch, Transmission, and Differential Work

Clutch service: Pedal and switch adjustment, master and slave cylinder replacement, and pressure-plate and clutch-disc inspection accompany the clutch replacement procedures.

Transmission internals: Clutch-housing and transmission-housing exploded views support mainshaft and countershaft disassembly, shift-fork clearance checks, synchro sleeve/hub and synchro-ring inspection, bearing and oil-seal replacement, and reassembly.

Differential procedures include backlash inspection, carrier-bearing replacement, and thrust-clearance adjustment. The separate driveline section details driveshaft and intermediate-shaft inspection, disassembly, reassembly, and installation.

Honda cautions that jaw-type pullers can damage mainshaft gear teeth; the intermediate-shaft procedures also identify the handling orientation needed to protect the differential oil seal.

Circuit Testing and Fuel-System Fault Isolation

Factory inspection criteria, special-tool references, and diagnostic procedures provide a working reference for planning and checking repairs on this EP3 configuration. DTC indexes, symptom charts, component-location drawings, and connector views connect reported faults with the relevant circuit and component tests.

Starting and charging: Clutch-interlock, solenoid, and starter performance tests accompany starter overhaul. Alternator/regulator circuit diagnosis, alternator control testing, drive-belt auto-tensioner inspection, and alternator overhaul are also covered.

Fuel and emissions: Honda PGM Tester/OBD II procedures include ECM circuit testing, fuel-pressure diagnosis, injector and sensor checks, VTEC-related DTC troubleshooting, and EVAP leak testing. The ECM idle-learn procedure is identified for applicable electrical and control-module work.

Wiring diagrams: Starting System, Ignition System, Charging System, and Cruise Control circuit diagrams support engine electrical diagnosis. ABS and HVAC circuit diagrams extend the electrical documentation to braking and climate control.

Chassis, Body, HVAC, and Restraints

Chassis repair: Steering-column service and rack-guide adjustment accompany EPS work. Brake coverage adds disc inspection, caliper overhaul, master-cylinder and booster service, and ABS wheel-sensor and modulator diagnosis.

Body and interior: Door-glass and regulator replacement, windshield and quarter-glass procedures, seat-cover work, and frame repair charts provide component-specific body information.

HVAC: Control-motor testing, evaporator and heater-core replacement, refrigerant recovery, evacuation, charging, leak testing, and performance charts accompany compressor-clutch service.

SRS: DTC and indicator-circuit troubleshooting uses dedicated simulator tooling. Deployment-related inspection, airbag and sensor replacement, and Occupant Position Detection System initialization are documented.

Honda Tool References and Service Precautions

Engine procedures reference the EOS02C000011 front subframe adapter, 07ZAJ-PNAA100 VTEC air adapter, and 07VAE-001010A valve spring compressor attachment. Clutch work identifies the 07JAF-PM7011A alignment disc; transmission, bearing, seal, hub, and ball-joint procedures identify their required tools.

Follow the manual’s safety precautions for fuel pressure, electrical isolation, brake work, refrigerant service, lifting, and SRS components before beginning repair work.

Sample Cold Valve-Clearance Specifications

The K20A3 valve-adjustment section specifies intake clearance of 0.21–0.25 mm (0.008–0.010 in.) and exhaust clearance of 0.28–0.32 mm (0.011–0.013 in.). These specifications apply with cylinder-head temperature below 100°F (38°C), alongside the valve-adjustment illustrations.