M-Class (W163) Produced 1998-2005: ML 230, ML 320, ML 350, ML 400 CDI, ML 430, ML 500, ML 270 CDI

ML320 throttle issue.

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Old 06-09-2021, 03:56 PM
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2002 ML320
ML320 throttle issue.

I have had my ML 320 for a couple of months now, and in general I'm really happy with it. It was pulling like a train.
Now, I have found that most of the power has gone. There are no warning lights, so I don't think it is limp mode. The first thing I did was put an OBD reader on it, but there were no codes. I checked the throttle position sensor, and on full throttle this is showing as 21.7%, which may go some way to explain the sudden power loss.

I had a look round the TPS, and all looked good. I had a look round the throttle pedal, and found a broken spring on the floor by the pedal, and the pedal has lots of play. I'd say there is a gap of about a half an inch between the throttle pedal when fully up and the throttle cable. I think that the broken spring must go in this gap. The spring is short and a compression spring.

My questions are these:
  • Am I right that this spring should be part of the throttle pedal assembly, and is causing the power issue?
  • If so, how do I get a new one? Are they part of the throttle pedal, the throttle cable or are they available on their own?
  • If not, what could be causing this slack in the assembly?
  • In the mean time, am I okay to fill that gap with something (nut and bolt, lump of waded up duct tape, end of a pen) or is doing that going to cause issues with the TPS?

I'd ideally like to get the power back ASAP, as pulling out in to traffic during rush hour needs more planning than usual at the moment.
Old 06-10-2021, 01:10 AM
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2002 ML 320 & 2006 ML500
You can buy the entire repair kit (#5) or just the spring (#7) or any other part you want.



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Last edited by Maj. Dundee; 06-10-2021 at 01:12 AM.
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Old 06-10-2021, 05:36 PM
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2002 ML320
Thank you, much appreciated. One quick phone call to my local MB dealer, and after parting with a whole one hundred and twenty six of my English pennies, I have one winging it's way to me from Germany.

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