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There's no mention of the cap's O ring in your post so I thought I'd mention it. Make sure you lube only the O ring with a little bit of oil before tightening the cap. Ensure it is on the correct "rib" before tightening and always use a new O ring when changing oil. It definitely is an odd problem.
Other thing I could think of is the filter brand. MANN is a more reliable OE replacement.
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