So, here's what we have so far. Anything else you all want to add?
01) Check and/or replace timing and balance shaft belts, if the belts are over 5 years old. Consider replacing the belt rollers and balance shaft seals at the same time. Gates and Dayton/Dayco belts have produced the best results for most of the Forum members. Even if you are not replacing the belts, check the orientation of balance shafts by removing the top cover and using the inspection hole on the bottom cover. It is surprising how often they are out of sync.
02) Check and/or replace water pump and thermostat.
03) Consider replacing the cooling fan switch to the lower temperature unit.
04) Replace plastic heater valve with an all-metal unit.
05) Replace the charging wire that runs from the alternator to the starter.
06) Replace the trigger wire that runs from the firewall to the starter solenoid.
07) Replace the exciter wire that runs from the firewall to the alternator.
08) Check the firewall for cracks around the brake and clutch cylinders.
09) Carefully inspect all vacuum lines for cracks and replace as necessary.
10) If over 100Kmi, consider replacing the ignition switch.
11) Replace dash bulbs, clean the contact posts on the circuit board, replace the odometer gears, and recover the light tunnels with foil or reflective tape.
12) If you have an ROW car (Not made for North America sales) check for fuel line corrosion where they tuck in behind the rear beam. They have been known to split and leak at that location.
13) Check date code on tires; replace if approaching or past 6 years.
14) Correct any maintenance unknowns, such as oil & filter age, air filter, fuel filter, distributor cap, spark plugs and wires. Be certain you use oil with the proper additives and good plugs and wires.
15) Inspect brake pads, flush and replace brake fluid if you are not sure it has been done in the past few years.
16) Drain and replace coolant, carefully bleed the air out of the system as per the Forum instructions.
17) Clean your MAF, and buy a spare DME relay to keep in your glove box.
18) Check and adjust accelerator pedal stop and cable.
19) Fix the power steering leak in the right front side over the steering rack bushing, replace bushings while you have the rack out.
20) Replace the clutch inspection port plug that has fallen out by now. A cut-down vent pipe plug from a hardware store works well and can be tightened so it will not fall out.
21) If over 120Kmi, consider having the head gasket and Variocam pads and chain changed at the same time.
22) If there is no replacement history, change the transmission fluid, The 6 speed transmission requires a special gear oil, use the proper stuff, replace the plug sealing washers, and expect that the plugs will be unnecessarily tight.
23) Adjust the parking brakes at the rear rotors. Wheels should lock tight with 4 clicks on the brake handle.
24) If you have a coupe, clean the sunroof drain tubes.
25) Avoid resetting the trip odometer when the car is in motion. Some have reported such behavior will destroy the odometer gears, others have had no problems resetting while moving.
26) Replace the radiator expansion tank cap. They are cheap, leak when they get old, and new ones look a lot nicer.
27) If your car has over 70Kmi and your starter motor sounds like it is dragging, you may have Gummy Starter Syndrome. Inspect and either lube or replace.
28) If over 70Kmi, inspect clutch. If clutch needs replacing, be certain to use the proper pressure plate. Consult the Forum for that part number. While in there, replace other clutch related items, such as the clutch arm needle bearings and the throw-out bearing.
29) If shifting seems sloppy, replace the small shifter bushings and the large nylon bottom pivot.
30) Get everything fixed at one time so you don’t have to worry later on, and stay up on a solid maintenance program!
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