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Looks like you done your research. Its great that you post with such detail. I m sure you know its only down to the exh cam gear or the cam seals(cam bearings). The only way to know now is to take them apart. From what i remember only eariler model n54 has the cam seals that would wear into the cam bearings, but that doesnt mean it wont happen even with updated cam seals. My "guess" would be the cam seal/bearing are worn just enough that only when oil gets thin(hot), it would leak enough oil pressure to cause the vanos system not work correctly.
What oil or oil weight you use currently? One thing you can try is to run heavier oil which should "delay" or lessen the fault from coming up.
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