Any 'crack' in the exhaust before the O2 sensor can cause a lean condition. Soapy water on a cold manifold might make the dealer a liar? Hard to believe that a crack didn't grow over 25 years!
Most parts stores will loan you a 7/8 O2 sensor removal tool. Yes, lots of PBblaster and patience. Getting that thing to move initially is hard, and you may have to tighten/loosen the sensor a lot of times before it comes out.
Volvo uses VIDA/DICE, but it needs an OBDII connection.
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Keeping it running is better than buying new
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