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1. Reduce the cars weight. Do not store anything in trunk, change your steel hood to an aluminum one (if available), or better yet a carbon fiber hood. If these are not an option, you can excise some extra metal underneath the hood.Using lighter aluminum rims instead of steels one will help as well.

2. Change that exhaust system. Any leaks in the exhaust will reduce horsepower.
Removing the catalytic converter and straigh piping the exhaust will increase the horsepower of your vehicle. Replace or modify the exhaust header. If you need more horsepower above 6000 rpm, an aftermarket header can provide another 3-4 peak HP. Useless unless cat-back exhaust upgrade done first.

3. Change that stock air filter to a perfomance air filter such as K&N.
Let air come in more easily - As a piston moves down in the intake stroke, air resistance can rob power from the engine. Some newer cars are using polished intake manifolds toeliminate air resistance there. Bigger air filters and reduced intake piping can also improve air flow.

4. Reprogramming the ECU. You can also add a chip. Some people
have argued that the horsepower chip does not increase HP, but others
have said they have had remarkable results with these chips.

5. Boost your octane.

6. Change your engine timing.

7. Replace the flowmeter in the intake tract. If you will be using the motor above 6000 rpm frequently this can provide another 5 or so peak HP.

The flowmeter is very restrictive and limits HP above 6000 rpm, replacing it eliminates the bottleneck. The OEM flowmeter flows 165 CFM while a bone stock 1.6 motor at 7200 rpm flows 178 CFM, this means that the OEM unit is undersized for high rpm usage, the change probably won't be noticed below 6000 rpm.

8. Shaving the head. Compression = power. Shaving the head .010" will increase the compression ratio about a /4 point. I dyno'd this and it was good for about 4 HP and 4 ft lbs of low rpm torque. It is very noticeable across the entire rpm range. (I don't know what the shaving limit is but I have not heard of anyone going beyond .025".

FYI, the shop manual limit is .008" for 1.6 and .004" for the 1.8). As long as you have the head off you might as well R&R the valve seats too. Cost about $250 if you remove and put it back on yourself.

9. Increase the compression ratio - Higher compression ratios produce more power, up to a point. The more you compress the air/fuel mixture, however, the more likely it is to spontaneously burst into flame (prior to the spark plug igniting it). Higher octane gasolines prevent this sort of early combustion. That is why high-performance cars generally need high octane gasoline - their engines are using higher compression ratios to get more power.

10. Increase displacement - More displacement means more power because you can burn more gas during each revolution of the engine. You can increase displacement by making the cylinders bigger.

11. Change Underdrive pullies - Usually consist of crankshaft and alternator pullies. These increase horsepower by reducing accessory drag. Pullies can benefit almost any engine, large or small. Installation is a snap, but there are a few disadvantages to underdrive pullies. Because the alternator is turning slower, it won't be able to produce the current needed to keep the battery charged when running at idle. If you leave your truck on idle for extended periods of time, you may want to only install the crankshaft pulley. An underdrive pulley set can add up to 15 horsepowerto your engine and can also improve fuel economy