At its most torn-down point:
In reassembly I learned some important lessons. First, if your car has EGR like mine does, I highly recommend hanging the exhaust manifold back on its studs and ensuring the EGR is connected with the flare nut at least snugged before you even bother with the hard-to-reach dipstick and manifold bolts you must access below the car. I fought with those only to realize later the EGR plumbing was misaligned. I found it easier to start the dipstick and manifold bolts from up top, by hand first, then go under the car and tighten them with two long extensions, one short extension, a wobble joint (not a u-joint) and the 12mm socket.
Second lesson, a lot of people reported having trouble with the three top manifold bolts that connect to the head. The common complaint was dropping the bolts into the abyss, only to have to remove the manifold and start over. I recommend use of one long extension, a wobble joint, and the 10 mm socket with a tiny bit of blue painter's tape to keep from dropping the bolt. Once it's threaded in, you can pull loose the socket/extension, the bolt will stay in place and you can remove the tape.
The intake ports and valves were perfectly clean on cylinders 2, 3 and 4. Cylinder 5 had clean valves but a bit of oil build up on the intake runner wall. Cylinder 1 was a little dirty, with oil build up on the intake runner wall and some on the valve as well. I think this is common as PCV oil follows engine vacuum and along the path of least resistance, right into the first cylinder. Hopefully some seafoam will clean it up.
Here's how clean cyls 2, 3 and 4 were:
Long story short, I got the whole thing put back together and after a drive pushing some turbo boost, I found oil sprayed all over the engine block and leaking under the car. I pulled it back apart and found the non-OEM Volvo oil trap was not sealed and therefore crankcase pressure + boost was spraying oil.
Here is the failed oil trap and resulting mess after 4 miles:
I had spec'd OEM Volvo hoses, but didn't think there would be a difference between the Volvo oil trap and the aftermarket one. Wrong! After re-doing the job all over again with an OEM oil trap from my local Volvo dealership (and after cleaning up a huge oil mess), here is the new oil trap in its final resting spot:
All back together and running like a champ.
Another maintenance item checked off the list.
Best Regards, SpeedyPete