Removing the intake manifold and gasket

• Remove the battery's minus cable. First read Battery, disconnecting .
• Drain the fuel system. See Fuel system pressure release .
• Remove the thermostat housing in accordance with: Replacing the thermostat and/or engine coolant temperature sensor .

Fig 1: Identifying Engine Compartment Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• the cover over the ignition coils
• the crankcase ventilation hose from the top of the cam cover
• the inlet hose from the throttle body (TB). Fold to one side
• the protective cover over the nozzle connectors
• the connectors from the nozzles.

Remove the mounting screws from the fuel rail.

Spray universal oil or similar around the injector nozzle at the terminal on the intake manifold.

Gently work the fuel rail and injector nozzles loose.

Separate the quick-release fuel line connector by pressing the blue clips on both sides. See Fuel line, lock .

Fig 2: Identifying Intake Manifold And Hoses

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove (only when replacing the intake manifold): 

• all 4 vacuum hoses from the intake pipes. (See the illustration)
• disconnect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

Remove: 

• the screw holding the dip stick pipe to the intake manifold
• the screw at the support bracket (under the intake manifold). Disconnect the connector for the throttle body (TB)
• unscrew the 4 uppermost screws completely. Slacken off the 3 lower screws a few turns
• the intake manifold. Lift the intake manifold approximately 20 mm  . Allow the crankcase ventilation hose to run through the intake manifold without disconnecting it from the flame trap
• the hose on the Positive temperature coefficient (PTC) nipple for crankcase ventilation. Lift out the intake manifold.