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I just changed mine a couple of weeks ago so it is still pretty fresh in my mind. Although some folks have changed it without pulling the manifold out, I found that I could see what I was doing a lot easier with it off than with it on. The turbo models do have a lot of hoses running along side the injector wires so it is pretty tight in that area with the manifold on. I had mentioned this in a previous post, but it is worth mentioning again. I highly recommend a 13mm swivel socket for pulling the manifold nuts off. You can easily remove all of them with a swivel socket. You would need to replace the gasket if you pull it off. The new Volvo gaskets are thick and soft so they work well.
Most of the vacuum hoses can be changed easily at any time so you don't necessarily need to do them during the same job.
I also very much agree with one of the other posts about being aware that not all connectors and cables will be replaced - don't damage anything unless you are sure it is on the new harness. You don't neccessarily need to label everything before you start, but it is a good idea to look at the harness and identify each connector before you start. The installation document you should have gotten from Dave is a good reference to check when you think you are done.
My only mistake was that there are two lugs on my starter and I connected to the wrong lug. There was no damage done, it just would not activate the starter. It was easy enough to figure out.
The only connectors that are hard to reach are the ones under the manifold and the oil pressure sensor. That one has to be routed from the bottom of the car near the harmonic balancer.
There is one really big connector near the ignition coil. It was very difficult to unplug so I cut the harness and pulled out 1 pin at a time. There are some unusual retaining clips on it so watch out for that. The connectors easily poped apart after that. Again, be absolutely sure you don't damage something that stays in the car. I found that cutting the old harness makes it easier to get out, but you can not make any mistakes. I used a razor saw to cut it in one or two places.
Mine took me about 6 hours. I was also replacing my injectors due to a gas leak so I removed and cleaned the manifold at the same time. It is a lot of work, but not that hard to figure out.
Good Luck,
R Duke
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