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Just thinking out loud:
When the ignition key is turned -- both on and off -- i hear clicking from relays in the engine bay, in the general vicinity of the air filter.
Is it possible that one of these controls or affects the flow of current to the starter, and is now failing (remaining open when it should close, or vice versa)?
Given their location directly over the hot engine, I would not be surprised if one of these, or some similar component, was the source of the heat-related problems.
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2008 E350 4matic / Black/Anthracite
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Gone but not Forgotten:
2001 E430 4matic, 206,xxx miles, Black/Charcoal
1995 E320, 252,xxx miles, Black/Grey
1989 260E, 223,00 miles, Black/Black
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