Re: Valve cover repeated failure
Another point to emphasize is when you're repairing the crankcase breather covers mounted on top of the valve covers, these are fastened by aluminum screws. These screws are a 1x use only. They are very susceptible to stretching when torqued too high and the proper torque setting is very low (4 lb-ft = 5-6 N-m). Mercedes-Benz states that these screws are to be disposed of if removed. So if you used these screws over again, and over-tightened them, your problem may be the screws.
Another point I found when I repaired my crankcase breather covers. I checked the tightness of the star point screws holding down the valve covers. In all cases, these screws were loose on both valve covers. Unlike pizzaguy, I did not remove the valve covers during the crankcase breather repairs. I just re-tightened these screws to the proper torque (10 N-m = 7.5 lb-ft). The valve covers on my XFire have never been removed or leaked. And I check these probably 1x/yr to make sure they are still tight.