I will preface this with the fact that I am not a 500E expert.
A customer of mine brought in his 500E to have me upgrade the brakes and do a transmission flush and fill.
Upon draining the fluid it because very apparent that the 722.3 gearbox needed a full overhaul.
I rebuilt the gearbox (including having to replace most of the steels inside the box). And reinstalled it. After that the car would not start. Didn't even want to try to start. I replaced the CPS as they are common failure points and then it almost attempts to start but not quite.
The LH showed a code 27. We replaced the LH with another and now get only 1 flash showing all is good. When cranking at this point the car would want to start but not quite fire up.
The customer believed it to be an issue with the insulation plates in the distributors and as the ignition leads were very obviously in need of replacement. We did an ignition tune up with all caps, rotors, leads, and insulation plates. The rotor adapter was the 06 40 so they were not replaced. Before replacing these parts in troubleshooting the car did show ignition timing at around 12 BTDC while cranking on cylinder number 1.
Now here is where it gets strange.
After replacement of caps, rotors, and ignition leads the car now shows 45 BTDC (vs 12 ATDC) during cranking with cylinder 1...... And no longer attempts to really start after doing that. This is where we are now and are a little stumped.
We have done a compression test and determined that all cylinders are 170-180 PSI (except cyl 1 which is a little off due to a slightly leaking intake valve, but not enough to prevent starting)
The car has 60 PSI fuel pressure and the pump runs the moment you put the car to the run position.
The upper engine harness has been replaced with new.
The lower harness has not been replaced yet.
All 3 magnets are on the ring gear and have not been disturbed. I can not find any literature which says that the ring gear must be installed in 1 direction.
The ignition leads were put on the following way.
Pass side (r)
Drivers side (L)
The coil leads were replaced 1 at a time so that they were not switched to be backwards. The rotors, cap etc. are bosch, with the wires being Bremi. All boots were installed with dielectric grease on the plugs.
If anyone has any suggestions, or even things to check, please let me know, I will check them and post back right away.