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ICQ>
Chuck; yes the intake has to be removed. If your car is a turbo, according to Steve the harness is cheaper. I bought mine for $190 from a mechanic/ friend at Volvo repair shop, so I may have found a great deal. As Steve says, they can run to $280 for the turbo GLT harness.
My advice would be to first diagram all of the wires and colors on the harness from where the wires go, to how many wires in the harness, to the colors/stripes on each wire in each connector. You will probably want to remove the alternator and intake so this task can be dealt with more easily. Of course, have your battery ground disconnected before starting. Have some new wire connectors w/ silicone boots for the harness at the firewall since it is deteriorated. I spliced on about 10" of new heat resistent wire here too since mine was just as gone as the harness itself.
Just have a good map of where everything goes before removing the old one, and the rest is pretty self explanatory. I don't know about the fuel sensor connection because I personally did not have this problem. My harness went in and worked fine as is. Good luck! the job is no fun, but once done, you will feel like you accomplished something! -Craig
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