2002 Hino Models FA FB FD FE FF SG Truck Workshop Manual PDF Download

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Basic Information Identification Make: Hino Model: FA, FB, FD, FE, FF, SG Trucks Year: 2002 Codes Chassis Codes: FA, FB, FD, FE, FF, SG Series Introduction Market Position Segment: Light...

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Sku: 68168

Tags: Hino Industrial Equipment & Tools Transmissions Gearboxes Vehicle Parts & Accessories

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Description

Basic Information
Identification
Make:	Hino
Model:	FA, FB, FD, FE, FF, SG Trucks
Year:	2002
Codes
Chassis Codes:	FA, FB, FD, FE, FF, SG Series

Introduction
Market Position
Segment:	Light to Medium Duty Commercial Vehicles
Application:	Urban delivery, local haulage, service vehicles, specialized applications.
Competitive Analysis
Competitors 2002:	Isuzu NPR/NQR, Mitsubishi Fuso Canter, Nissan UD trucks, Ford E-Series Chassis (depending on market and configuration).
Key Features
Vehicle Philosophy:	Hino trucks are known for their durability, reliability, fuel efficiency, and ease of maintenance in the commercial sector.
Manual Value Proposition
Benefits:	Enables self-sufficiency for maintenance and repair, reduces downtime, provides accurate technical data for efficient servicing.

Manual Details
Coverage Areas
Market:	Global (Hino is a global manufacturer, manual content likely reflects common international specifications)
Vehicle Types:	Light to Medium Duty Commercial Trucks
Page Count
Estimated Pages:	High (typical workshop manuals for this class of vehicle can range from 800-1500+ pages, covering multiple models and variants)
Manual Type
Type:	Workshop Manual / Repair Manual
Language
Language:	Likely English (standard for international workshop manuals, though regional variations may exist)
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine:	Detailed diagnostics, overhaul, component specifications, removal/installation procedures, timing, cooling, lubrication, fuel delivery, emissions control, turbocharging (if applicable).
Fuel System:	Fuel pump, injectors, filters, high-pressure lines, electronic fuel injection (EFI) system diagnostics and adjustments, common rail systems (if equipped).
Lubrication And Cooling:	Oil pump, oil filter, oil cooler, water pump, radiator, thermostat, coolant circulation, lubrication points, oil change intervals, fluid specifications.
Transmission Drivechain:	Manual and automatic transmission overhaul, clutch assembly, gear shifting mechanisms, drive shafts, differentials, axle ratios, joint maintenance.
Steering System:	Power steering pump, steering gearbox, tie rods, steering column, alignment specifications, troubleshooting steering play.
Suspension Shocks:	Shock absorbers (dampers), springs, control arms, bushings, wheel hub bearing replacement, suspension geometry specifications.
Brakes:	Hydraulic brake system diagnostics, master cylinder, wheel cylinders, brake calipers, brake pads, brake shoes, brake rotors, brake fluid specifications, parking brake system, ABS (if equipped).
Electrical System:	Wiring diagrams, fuse/relay identification and function, battery, alternator, starter motor, lighting system, instrument panel, ECUs, sensors, diagnostic connectors (e.g., OBD-II or proprietary Hino diagnostic port).
Body Work:	Exterior panel removal/installation, door mechanisms, interior trim, cab mounting, body sealing, corrosion prevention.
Intake Exhaust:	Air filter replacement, intake manifold, exhaust manifold, muffler, catalytic converter (if equipped), turbocharger (if applicable), emissions system components.
Diagnostics:	Covers diagnostic procedures for engine, transmission, ABS, and other electrical systems. Includes symptom-based troubleshooting guides and fault code interpretation (if applicable).
Procedures Included
General Information:	Vehicle identification, safety precautions, jacking and lifting points, general torque specifications.
Routine Maintenance:	Fluid level checks and top-offs, filter replacements, lubrication points, tire pressure checks, belt inspections, battery maintenance.
Engine Removal Installation:	Step-by-step instructions for removing and reinstalling the engine, including required tools and lifting equipment.
Advanced Troubleshooting:	Diagnostic charts, symptom-based troubleshooting, electrical system diagnostics, using scan tools, identifying common faults and their remedies.
Engine Overhaul:	Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, crankshaft), cylinder head work, and reassembly with correct torque specifications.
Transmission Repair:	Step-by-step guide for removing, disassembling, inspecting, and reassembling manual and automatic transmissions, including gearset replacement, bearing services, and shift mechanism repairs.
Technical Depth
Depth:	Comprehensive (covers routine maintenance, diagnostics, component-level repair, and major overhauls)
Specifications Detail:	Includes critical technical data such as torque specifications, clearance measurements, timing marks, diagnostic values, and fluid capacities for all major systems.

Manual Specifications
File Format
Quality:	High-resolution PDF, ensuring clarity of diagrams and text for printing and digital viewing.
Searchability:	Likely text-searchable PDF, allowing for quick access to specific information.
Version Control:	PDF format ensures the content remains static and accurate, as it's a digital reproduction of the original factory manual.
Print Quality
Printability:	Designed for printing specific pages as needed, avoiding damage to the entire manual.
Diagram Clarity:	Essential for clarity of complex wiring diagrams, exploded views of components, and assembly procedures. High-resolution PDF ensures these are legible.
Binding Type
Digital Binding:	N/A (Digital PDF)
Paper Type
Digital Paper Emulation:	N/A (Digital PDF)

Engine Specifications
Primary Engine Options
Potential Engines 2002:	Hino J05C series (e.g., J05C-TC), Hino W04 series, potentially Hino N04C series. Specific engine designations will vary by model and region. Common configurations include 4-cylinder and 6-cylinder diesel engines.
Performance General
Horsepower Range:	Typically 140-215 HP (approximate range for 4.0L to 7.0L diesel engines of that era).
Torque Range:	Typically 300-500 lb-ft (approximate range).
Fuel System
Injection Type:	Likely Indirect Injection (IDI) or early Common Rail Direct Injection (CRDI) depending on engine variant and emissions standards.
Fuel Type
Type:	Diesel
Cooling System
Type:	Water-cooled, pressurized system with thermostat control.

Transmission
Standard Transmission
Type:	Manual Transmission (e.g., 5-speed or 6-speed)
Optional Transmission
Type:	Automatic Transmission (less common in this class, but possible for specific applications or markets)
Features
Clutch:	Hydraulically actuated, single dry plate clutch.
Drive Axle:	RWD (Rear Wheel Drive) is standard for most models. Rear axle ratios will vary based on intended duty cycle.

Dimensions
Exterior General
Gvwr Range:	Class 3-5 (e.g., 12,000 lbs to 26,000 lbs GVWR), depending on specific model (FA, FB, FD, FE, FF, SG).
Wheelbase Range:	Highly variable based on model and chassis configuration, typically ranging from 100 to 180+ inches.
Tire Sizes:	Commonly 225/70R19.5, 245/70R19.5, or similar heavy-duty truck tires. Specific sizes depend on GVWR and axle ratings.
Weights
Curb Weight Estimate:	Ranges from approximately 6,000 lbs to 12,000 lbs, depending on body configuration and options.

Safety Features
Ratings
Federal Safety Standards:	Compliant with Federal Motor Vehicle Safety Standards (FMVSS) applicable to commercial vehicles of its class in the United States (e.g., braking, lighting, occupant protection).
Active Features
Braking System:	Hydraulic disc brakes on front axle, drum brakes on rear axle. Parking brake typically operates on rear axle. ABS (Anti-lock Braking System) may be optional or standard depending on configuration.
Passive Features
Occupant Protection:	Seat belts, reinforced cab structure, padded dashboard. Limited passive safety features compared to modern passenger vehicles.

Technology Features
Infotainment
Features 2002:	Basic radio (AM/FM), potentially cassette or CD player. Limited to functional necessities rather than entertainment systems.
Driver Assistance
Features 2002:	ABS (if equipped), power steering. Advanced driver-assistance systems (ADAS) were not prevalent in this vehicle class at this time.
Connectivity
Features 2002:	Basic vehicle diagnostics via proprietary diagnostic port. No integrated Bluetooth, USB, or Wi-Fi features.

Maintenance
Service Intervals
Oil Change:	Typically every 5,000-10,000 miles or 6-12 months, depending on operating conditions. Consult manual for specific interval and engine type.
Air Filter:	Inspect every 10,000 miles, replace as needed or every 20,000-30,000 miles. Severe duty may require more frequent replacement.
Fuel Filter:	Replace every 15,000-30,000 miles or as per manual recommendation. Crucial for diesel engine health.
Fluid Specifications
Engine Oil:	Typically API CI-4 or higher rated diesel engine oil, viscosity grade SAE 15W-40 or 10W-30 (refer to manual for exact specification and capacity).
Coolant:	Hino Genuine Coolant or equivalent (e.g., ethylene glycol-based with appropriate corrosion inhibitors). Typically a 50/50 mix with distilled water. Capacity varies by model.
Transmission Fluid:	GL-4 or GL-5 rated gear oil for manual transmissions, specific ATF (Automatic Transmission Fluid) for automatics (if equipped). Capacities vary.
Brake Fluid:	DOT 3 or DOT 4 Hydraulic Brake Fluid (refer to manual for specific type).
Known Issues
Common Wear Items:	Clutch wear, brake pad/shoe wear, suspension bushings, exhaust system components, turbocharger (if applicable) seals, injector seals, glow plugs (in cold climates).
Diesel Specific:	Fuel system maintenance (filters, injectors) is critical. EGR (Exhaust Gas Recirculation) system can accumulate soot. Turbocharger maintenance is important for longevity.

Vehicle History
Brand Heritage
Manufacturer:	Hino Motors, Ltd. is a Japanese manufacturer of commercial vehicles and diesel engines, a subsidiary of Toyota Motor Corporation.
Model Evolution
Lineage:	The Hino FA, FB, FD, FE, FF, and SG series represent Hino's long-standing presence in the light and medium-duty truck market, evolving over decades with new engine technologies and chassis designs.
Production
Manufacturing Locations:	Primarily Japan, with global assembly plants in various countries.

Awards & Recognition
Recognitions
Industry Perception:	Hino trucks are generally well-regarded in the commercial vehicle sector for their robustness and operational cost-effectiveness. Specific awards for model year 2002 are unlikely to be widely publicized.