Hi all,

I have been contemplating doing a LS swap into an E39 touring/wagon. I have spent quite a bit of time reading the many (well, few very detailed) threads on the subject, though most don't seem to quite fit my exact situation. I suppose I should start with why I want to do this.

My daily driver is a C5 Corvette, and it's been great and reliable. However, there is the occasional time where I need to haul things (and people) around, and the Corvette is just too small for that. Currently have an E320 for that purpose, but the trunk is on the small side and it technically belongs to my mom. I have considered sedans like the first gen CTS-V, 550i, etc, but decided that a wagon would be far more suitable for my needs (I end up hauling things about once a week). However, high performance wagons with a manual transmission are relatively rare and most are way outside my price range (2nd gen CTS-V wagon). Came across an article on a LSX E39 touring (Jesus Freak's wagon), and decided that might be a viable option for me. Additionally, I am of the tinkering type, and not afraid to do work myself and get my hands dirty.

My intention is to set up the car as a daily driver and a sleeper, though it probably won't get driven everyday. It will most likely get used on long road trips. However, the primary hurdle to whether or not I even get this project started is whether or not I can make it smog legal in the totalitarian state of California. From what I have read, the most difficult challenge is getting headers that are CARB legal. I have seen people mention that first gen CTS-V headers might work, LSA headers may work, and 5th gen Camaro headers might work with minimal modifications. Those mentions have been one off mentions that didn't have any pictures or anyone else backing them up that I can find.

I am not stuck on the E39 wagon, I am also considering the Volvo V90 as well. The primary problem with the V90 is that they are quite hard to find, though quite cheap when they are found. I'm also watching a E60 build thread with interest, but once again, headers seem to be an issue with the steering shaft; the Hookers are quite close, though it is mostly due to the flange being right there at the steering shaft. I don't know if there are any GM headers that hug the block as tightly as the Hookers. There is also the problem of E60 wagons being AWD and much more expensive.

Any thoughts or inputs would be greatly appreciated. All I'm doing right now is just doing research, trying to decide whether or not this project is something that stands a chance of being successful. Of course, maybe the most logical thing to do would be to find a 540 wagon and just swap in a manual transmission. Doesn't seem like the US ever got the 550i wagon.

tl;dr: Want to do an LS manual swap into an older wagon in the draconian state of California, need help figuring out if I can make it CARB legal.

 

As long as the engine is newer than the car, and all engine-related emissions gear is in place (there is very little, besides converters) plus the evap system is working, you should be good. Header-wise, you might consider the Hooker cast manifolds as they flow well and look stock. Some LS manifolds would fit and flow well too.

 

Thanks for the reply. The Hookers might fly if the referee was inattentive, but that is not something I want to bet on.

 

Search on the BMW forums as their are a couple of guys who have done the swap and made it carb legal

 

I must be blind or not using the right search terms then. 2 evenings on Google searching up this stuff has yielded me no builds in California.

Anyone know anything about the Patriot Exhaust Products H8080?

 

In addition to feedback from those on the site and, hopefully, those who have succeeded --- I'd plan on having a long talk with the folks that will actually make the judgment about whether it can be CARB legal or not. Those doing the inspecting wherever you reside in that lovely state where there are a lot of people that are "here to help you".