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Author Topic: BP Swap  (Read 18062 times)

Rocketman

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BP Swap
« on: September 24, 2013, 11:02:26 AM »

The 1.8L Mazda DOHC known as the "BP" engine is becoming a more common swap into the Capri. There are JDM versions with a turbo, known as the BPT & BPD. They come from a second gen 323 (BG chassis) GTX & GTR, respectively. The BPD has the highest power output, around 210hp. IIRC the BPT puts down 180hp.

The nonturbo BP was available here in the states in the Ford Escort GT, some Mercury Tracers, Mazda Proteges and some Kia's in FWD format. Certain year Miata's also came with a BP but they're RWD, necessitating location of all the FWD accessories. The "best" option is the Mazda Protege BP closely followed by the Escort GT, they are the closest match to our cars.

Physically, the BP is about an inch longer than the stock 1.6L engine. This creates clearance issues. Also for this reason, the manifolds do not interchange. You will need a complete BP with manifolds.

Off the top of my head, here are the physical modifications needed to fit an Protege/EGT BP into a Capri XR2 (will go over NA further down)
-Clearance the passenger framerail. This can be done by cutting/welding or creative use of a hammer. You will need an additional 1/2 to 3/4" around the engine & alternator pulley.
-Passenger engine mount will need work. You will need to swap the B6T engine bracket onto the BP & cut the timing cover backing plate to go around it. The B6T unit *may* work. The mount will be further over, slot the 3x holes on the mount itself and slot the bolt holes in the bracket on the vehicle to move it further toward the fender.
-The fuel lines on the BP are a different location. Use correct high-pressure fuel injection hose to route new ones. The Protege uses barb style fuel rail (like stock) the Escort uses quick-disconnects. If you end up with an Escort engine, try to source a Protege fuel rail.
-The throttlebody & intake tract will be re-located. You will have to come up with a whole new intake piping system. This will depend on turbo/na applications & is up to you. Note that the BP throttle will be very close to the brake master cylinder, using a silicone coupler/bend here with a tight radius can help with clearance.
-The exhaust downpipe will be in a different location. Plan on fabricating a new downpipe for both NA & turbo BP swaps
-If mated to an XR2 transmission, the oil pan will not bolt up in all places. Just bolt together what does line up - the other bolts are not critical.
-The XR2 intermediate shaft will no longer line up with bolt bosses on the block. By welding on an extension to the bracket & re-drilling it can be made to fit. You can also source a newer Kia axle which deletes the intermediate shaft but may have unknown effects on torque steer.
-The throttle cable does not fit the BP throttle as-is. The throttle cam can be modified to accommodate it but there may be better solutions - maybe swapping a stock cam gear onto it?

I believe that's it for the physical work, there may be small details I am looking over. It's been several years since I did the swap.

Electronics:
I do not have a writeup for electrical concerns with the BP. If you have a turbo BP, you can use XR2 electronics - ecu, harness, injectors, distributor, knockbox, etc. If you buy a JDM BP with harness, try using it. Use the stock start/charge harness, it is separate.
If you are swapping in a nonturbo BP, I would recommend using the BP harness, ecu & electronics. The BP harness and B6 harnesses have a bulkhead connector where they connect to the body harness - you will need to sort out a dozen or so wires here, it shouldn't be too difficult. Things like power, switched power, gauge signals and such travel through here. If you get to this point I will be happy to help sort it out.

Notes for N/A capris:
I have seen a BP swap on an automatic capri before. This seems viable, though I question the reliabilty of the transmission.
The nonturbo manuals capris have an F-Series transmission. The BP will indeed bolt to this, but you are at a disadvantage. The clutch and flywheel are smaller, and will definitely need an upgrade to hold the BP's power. Beating on it will more than likely result in a blown f-series transmission, they're just not build to hold that kind of power.
-The N/A manual capris could benefit from swapping the whole BP + protege/egt transmission. This is a whole new can of worms but a good option. You will need Capri XR2 axles (or the capri/kia combo mentioned above), and the engine mounts will need different modifications from those discussed above. The BP transmission is different - it tilts the engine forward several degrees. It is also hydraulic so the stock clutch master cylinder can be used.

Hope this helps, sorry it may not be super clear but there's a lot of possible BP engines into a lot of possible Capri options, lol. If you need clarification please ask!
« Last Edit: September 24, 2013, 11:05:30 AM by Rocketman »
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Advancedynamix

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Re: BP Swap
« Reply #1 on: February 10, 2014, 10:11:52 PM »

Been thinking about going BP in my XR2.  I have all the stuff necessary to BPT it, and I am pulling the b6t to reseal it and do a clutch anyway, so why not just bite the bullet and go big. Has anyone other than Matt (thank you for the write up Matt) done this swap?
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Rocketman

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Re: BP Swap
« Reply #2 on: February 11, 2014, 08:32:39 AM »

I've seen 5 or 6 other Capris with a BP swap.

There was a gent on the Yahoo! group who swapped one into his Automatic
There was someone in New jersey who had a BPT swap with a custom turbo setup, but wanted crazy money ($7K?) for it. Engine looked good but the rest of the car looked hacked. Not sure whatever happened to it, this was 4-6 years ago
Dean Fayzal from Australia has a two show cars, one a 100% chromed B6T, the other has a BPT. He's on here, but I don't see him much
There's another red capri in Australia with a BP and some absolutely massive crazy huge turbo bolted to it, if it spools at all I'd be surprised lol

That's what I can remember off the top of my head. there's probably more undocumented swaps out there
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fchalvet

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Re: BP Swap
« Reply #3 on: June 30, 2014, 06:21:30 AM »

I need help please!
I left my NA capri to someone who had done a BP swap.
But He didn't finish his job and I try to find a solution. It's even almost impossible to put the 1.6 back, as I have lost a lot of parts, fuse box, etc..

Right now I have the BP ECU and harness.
However I'm completly lost to connect the black connector from the Capri harness to the BP harness, on the passenger side.
Also I have the BP fuses box, and my other problem will be to connect the Capri harness on it, for the lights, etc
Hope someone can help me
Thanks
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Rocketman

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Re: BP Swap
« Reply #4 on: June 30, 2014, 08:13:01 PM »

I think you need to keep the Capri charging harness & fusebox.

The wiring on the big black connector is pretty straight forward, admittedly I have not done it myself though. You will need a diagram for the Capri connector, and one for the BP connector, the wires are mostly all the same just different location.

There is a BP swap wiring guide on the Yahoo! 323 GTX group. It's from the early 2000's, I don't know how accurate it is - but might be worth looking into
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fchalvet

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Re: BP Swap
« Reply #5 on: July 01, 2014, 01:10:14 PM »

Thanks for your answer.
Yes I thought that I would need to use the Capri fusebox. I will try to find it back...

I have the Capri book but it's not good to use...maybe the 323 will work better if I can find it. And yes the BP diagram too.

I will try to see in the GTX group if I can find something
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azgtx

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Re: BP Swap
« Reply #6 on: July 01, 2014, 08:29:08 PM »

Why didn't you just run the BP off of the Capri B6D electronics?
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fchalvet

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Re: BP Swap
« Reply #7 on: July 02, 2014, 05:55:08 AM »

For now I want to try that way...this engine is supposed to be something like 170hp, with a special Ecu , cylinder head, 1.3L gearbox, etc
But I'm still not sure to have my parts back, the fuse box and the charging harness...this guy stole me!
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fchalvet

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Re: BP Swap
« Reply #8 on: July 02, 2014, 05:57:58 AM »

Anyway, here a pic of it

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Rocketman

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Re: BP Swap
« Reply #9 on: July 02, 2014, 06:57:46 AM »

1.3L gearbox??

That engine is not mounted down is it? From the picture it appears to be sitting at some crazy angle, as if it were using the stock BP passenger mount/bracket. You have to use the Capri bracket/mount with some modifications
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fchalvet

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Re: BP Swap
« Reply #10 on: July 02, 2014, 08:08:09 AM »

1.3 gear box so you can use a lighter flywheel then more torque

I agree with you about the engine. yes it's mounted down and not right.
The guy said that he used the Capri mount and then a custom one, made from the 323...
I probably will have to change that if I decide to keep this engine
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Rocketman

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Re: BP Swap
« Reply #11 on: July 02, 2014, 09:42:07 AM »

The 1.3 gearbox is horrifically weak and not rated to take the tq of a BP. You need to get the stock gearbox back.

There are aluminum lightweight flywheels available for the 1.6 and 1.8L engines, that weigh in at ~9lbs which is lighter than the 1.3 flywheel. It has no effect on 'more torque' though - it frees up some mass so the engine revs free, and makes the care more agile to drive - but overall total tq stays exactly the same
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fchalvet

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Re: BP Swap
« Reply #12 on: July 02, 2014, 11:07:09 AM »

I don't know..the guy  used  this gearbox for long with all his 1.8L engines and has never broke one.
I tried his 323GT 160 hp and the car was amazing with it.
Anyway as I said I'm not sure to keep this engine, and if I do then I will have to buy a 323 to get all the missing parts..so I will have a stock gearbox in case
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chrispoe

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Re: BP Swap
« Reply #13 on: July 02, 2014, 11:28:01 AM »

I agree with Rocketman, get your old tranny back. The 1.3l tranny is a E series and won't hold more then 100 ft/lbs of torque reliabily.
The F series transmission is good up to 150 ft/lbs and the G series transmission is good for 200+ ft/lbs.
Both the F and G transmissions are more then strong enough to hold a N/A BP.


Try to get your old wiring back, but if you can't get your old electronics back, I do have my old electrical notes for wiring the BP engine into my Capri.  It uses the BP's charging and engine harness with fuel relay,  and the BG chassis fusebox from an escort GT.
« Last Edit: July 02, 2014, 03:42:25 PM by chrispoe »
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Rocketman

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Re: BP Swap
« Reply #14 on: July 02, 2014, 06:51:38 PM »

I don't know..the guy  used  this gearbox for long with all his 1.8L engines and has never broke one.
I tried his 323GT 160 hp and the car was amazing with it.
Anyway as I said I'm not sure to keep this engine, and if I do then I will have to buy a 323 to get all the missing parts..so I will have a stock gearbox in case

Keep the engine! There are not nearly enough BP swapped capris out there. Where are you from, btw?

The E trans is junk, ive seen many shredded ones on FordFestiva.com where they put all sorts of engines up to them. Theyll hold if you baby the car but what fun is that? The XR2 trans is a holy grail for them for swap purposes because it can hold some extra power.

You could source an escort GT transmission which will is another G series but it mounts differently, it may work better with the BP though
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