This seemingly simple job took me the better part of the day between removal and installation. You just have to be patient, and take a break when it gets frustrating. I eventually got them back in but not for any particular reason. This job would still take me a very long time if/when I do it again.
I pretty much gave up trying to get the cover on with the gasket seated, it kept falling off(especially in the back near the firewall where there is large semi-circular gasket piece). I laid the gasket in place on the engine side, and then focused on getting the cover back in place positioned over the studs. Once I had that, I had enough play to get the gasket seated and then the cover didn't take much work to set in place on the engine. As a test, I put the gasket sealant on one cover and none on the other. So far no leaking from either side.
Also be careful when tightening the cover back up. I can't remember if there is a specific order or not, but definitely do it slowly in increments for each one-- and don't over torque them.
Last edited by bbig119; 10-02-2006 at 01:45 PM.
'94 540I 6spd/205000 miles