I'm going to be posting some videos and pics in another thread. I have some more filming to do first. My lil' 3.0 sounds pretty mean and might give you some ideas. Definitely pretty quick. I'll let you decide. The one thing I wanted to share right off the bat was a tuned ECU that I purchased off ebay that I absolutely love! I've been running since this spring. (I've shared it privately with other members----- hang tight Tecboy99). I can speak from experience having run the shark injector, as well as the stock tune the 3.0 came with. The tune I am running is a modified BMW Euro 2 tune. The ignition tables are stock (for reliability), but everything else is adjusted. Feels like a different car! Ill send you his link. You have a ton of options, and on top of that, you keep your stock ecu unaltered. Instant swap. No issues/worries with bricking it. You can always re-tune the modifed version to fit your needs. Technically you can flash your own for free, etc, but I wanted a good place to start tinkering. The whole deal costed $175 bucks and in my opinion, is worth it.The seller is awesome, great to work with and will tune it how you want it within reason. Check out the listing for details. I'm running cat-less headers for the last month, and it works even better. I like it better than the shark injector tune. Hate to say it, but seems hotter. Just the butt dyno and opinion here....
BMW E46 E39 M54 Tuned ECU EWS Delete Headers 330 325 530 525 x3 X5 | eBay
Next subject, AFE Intake. Works great, except it still pulls some hot underhood air. I'm about 20 degrees warmer than ambient temp. That said, my headers are adding some heat to the fire. I've been running Dash Command and have been monitoring the Intake temps. I will put the stock airbox in for a day and let you know. I'm going the custom route, to try a few things as well. I've got a pile of mods to do still, but I think I'm doing the custom intake very soon.
Next subject, Exhaust. Losing the rear muffs(do it!) adds some ponies, some mpg gains and depending on what you replace it with, some drone. 2-2.8k is what I'm dealing with. Its not bad, I just notice it more. There are some things to try including a j-pipe or hemhlltzer (spelling?) pipe. I'm also cutting the middle resonator out and putting in a resonated x-pipe. Magnaflow and Jones both make one. The Jones is half the cost and uses ceramic packing and rock wool I believe. I'm running their Areo ceramic packed AR20's as the rear mufflers and they sound great. The Magnaflow straight through 4 inch rounds (4''x 24'' I think?) sound amazing too. I ran that on my previous I6 E53 with and without headers, and sounded great both ways, come to think of it, amazing with headers. I think the magnafows delt better with the drone as they were longer, and were packed with only rock wool. (rock wool has a shorter life compared to ceramic, but acoustics seem different, perhaps better?)
Ton of info and opinions here to digest. I think your expectations and goals are realistic and very easy to reach with not much money which is a bonus.;)Check out e46 fanatics. They have TONS of info! Hopefully I've helped. There most definitely is some marginal power/fun factor left on the table. My E53 6M is a total different animal and I've loved watching the transformation. I could have bought a 4.4 or 4.8, but my 6M for me is something special and unique. I will be going forced induction ultimately at some point, but for now, I'm loving it as it is. Good luck and keep us posted.