I Finally got the hollow screw from the local Volvo dealership yesterday and finished up the job. In the end, this job is a PITA: sore back, sore knees, sore fingertips, coolant all over the floor.

My hands aren't particularly big but I still had to remove a few more items from the engine compartment to make room to work:

- upper radiator hose (radiator to thermostat housing)
- dipstick
- rubber intercooler pipe (connects over-engine tube to intercooler)
- wiring harness mounting plate (bolted to head on driver side)

The trickiest part is re-connecting the new breather tube assembly. One end attaches to engine head on driver side and the other attaches to the underside of intake manifold. The space one both ends is incredibly tight, so there is little room for tools (hence the sore fingertips). Be prepared to catch the coolant that will flow once you unplug the hole on the head (driver side) to attach new breather tube, I suggest going a bit slower and getting it in on one go vs. rushing and dropping the screw (and washers) all while watching the coolant flow. Attach breather tube on the intake side before connecting it to the oil separator and thermostat housing nipple, this will give you more play on the tube to work with. Attach breather tube to intake manifold before connecting intake anything else.

After this it's just putting everything back together. I went in this order yesterday:

- connect breather tube to head
- connect breather tube to intake manifold
- connect air intake pipe to throttle body
- mount intake manifold (with new gasket), don't tighten bolts yet
- connect fuel pipe to fuel rail
- connect breather tube to oil separator
- tighten intake manifold bolts
- connect breather tube to thermostat housing
- connect valve cover to oil separator hose
- connect vacuum lines to intake manifold
- connect wiring: injectors, fuel rail pressure sensor, thermostat, throttle body
- connect upper radiator hose
- re-attach wiring harness plate
- connect wiring: ignition coils
- re-install air box/MAF meter
- re-mount wiring harness with zip ties
- mount ignition coil cover, fuel rail cover
- re-install dipstick
- re-install intercooler hose to over engine tube to turbo
- re-install strut brace
- ADD COOLANT

That's all folks!