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It's reasonably straightforward.
As I recall from doing this on a '94 960, you have to get the alternator out of the way, and this requires removing the bolts that anchor the power steering pump.
You don't have to remove either of these items, but you do have remove the bolts so that you can move them somewhat.
There is a bolt at the lower side of the thermostat housing that is somewhat blocked in access by a bracket that has something to do with the A/C compressor & alternator mounting. It's a large Torx; about a T45; the same size as the ones that fix the thermostat cover to the housing.
I got a somehwat long Torx bit from the SnapOn guy (~3 inch long), and I may have had to file a bit of a notch in the top of the aluminum bracket with a round file to get access to the lower bolt.
Who knows, they might have changed this on the late 960/S90/V90, but I wouldn't count on it.
Anyway, that was the only pain about the whole thing.
I might also add that oncy I had the housing off, I lapped it with sandpaper (320 to 400 grit) to get it flat. It wasn't flat and that is why it developed a leak. I would suspect that yours may have a similar problem.
I wouldn't do the silicone gasket, just get the gasket from Volvo. It will be cheap, and I've found the green Volvo paper gaskets to be quite good as far as paper gaskets go. If you make sure that mating face of the housing is flat and repalce the gasket, then you won't have a problem again.
Lap if 'figure 8' strokes/pattern to keep from rocking and making the surface domed. Machinists use this technique all the time.
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