1) Completely disconnected and removed intake manifold/throttle body assembly from car. This required disconnecting all vacuum lines, electronic connections (FI, pressure sensor, TB, etc.), intercooler to TB pipe, fuel pipe (to fuel rail), and passenger side breather tube (from underside of intake). Fuel pipe took a bit of time since the fitting is tight [squeeze green buttons, push in then pull out]. Since the assembly was out, I cleaned the manifold and TB with TB cleaner. Found a small pool of oil in intercooler-TB pipe so I removed that and also cleaned it with TB cleaner (I suspect this might be coming from my leaking turbo; maybe caused by plugged PCV?).

Intake manifold gasket removal required cutting old gasket on last bolt (pass. side) since the bolt can't come out all the way; it hits the thermostat housing. Looks like I'll need to cut the new gasket to go around the bolt because I don't want to remove the thermostat unit just to remove the bolt.

2) Removed old oil separator, breather tube, valve cover hose. Oil separator lower retaining bolt is difficult to access, need 6" extension on 10mm socket; tight squeeze as this will rest right up against alternator - need to work around dipstick tube and turbo to intercooler hose.

Disconnecting breather tube from engine head (at thermostat housing) will open up breather cooling line (both ends) so be prepared to catch/stop fluid. I bought rubber caps to CAP off nipple on thermostat housing and PLUG hole on driver side (engine head) to stop coolant loss after removal. Disconnecting breather tube on driver side required disconnecting wiring harness (from coils) and moving it to access the hollow screw connecting the breather coolant line to engine head. Even so the space is very, very tight. Be sure to keep the two little washers from the hollow screws on both ends of breather tube.

3) Install new oil separator, breather tube, valve cover hose, intake gasket...

I had to stop because somewhere along the way I lost the hollow screw for the driver side breather tube coolant line. Had to special order the part from local Volvo dealer today (part number 8653883); takes 2 days and costs $14.80, ouch. From here it seems pretty straightforward and should go much more quickly.

I'll add pictures once I have them organized.