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You do not have to remove it! I just redid mine 3 days ago, here's how:
Raise the sunroof to the "vent" position. Unhook the spring clips that hold the 2nd half of the sunroof headliner up when in this position (You have to gently pull down & back on that part of the headliner from outside and you will see these, about 3" in from each side. They slide up and out of two metal brackets on the insert). Close the sunroof. The back drain hoses are held up by hangers. Pull the hose up out of the hanger, but do not remove the hoses from the pan. Remove all bolts EXCEPT the ones across the front of the sunroof pan. Start at the front and work back. Gently lower it until they support the pan.
Sitting in the back seat, look between the pan & roof. This is the where to remove the insert. The sunroof headliner will snap out of place if pulled on. May require a bit of pulling back, then pushing forward (be gentle). You may also want to try slight rocking (side to side angling) of the headliner insert. Pull it out the back.
The vent position insert can be remove from the main by: Place on a workbench (table, etc.) and lift the insert to full open. Look at the hinges, the vent insert is two simple L shaped wire prongs into the main insert. If you place the whole sunroof insert face up, with the front towards your body (vent insert will open towards you) all you have to do is pull towards the right (may be left, but you'll see what I mean when you get it out and to this point). Reverse above to reinstall the vent insert.
I wouldn't use spay adhesive on the sunroof headliner. Volvo used a doublesided type of thin tape (or possible a gummy glue lightly spread). I had some white paper thin double sided tape that was very sticky, and used this to supplement the Volvo stuff (which stayed sticky and on the insert when I pulled off the old material!) You DO NOT want any adhesive applied on the face side of the inserts or the back of the material covering these areas. Apply the adhesive (tape, etc.) on the back side of the inserts where the edges of the material will be secured. Make sure to stretch the material slightly.
When putting it back in the car, just reverse the above. You may want to lay a piece of plastic (large yard garbage bag) on the pan to protect the new material from any crud in the pan. Align it in the track and push forward. You may have to angle it to get the clips to work in. It should, once the clips are in, slide up to the front and snap into place. Rebolt the pan and place the hoses back in their hangers. Once this is all done, open the sunroof to "vent" position and reattach the springs. You're done.
Good luck!
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MD
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