In 1990, the Paris Motor Show witnessed the unveiling of a vehicle that would soon become a legend – the Mercedes-benz 500 E. Launching in the spring of 1991, this model masterfully blended the luxurious comfort of a touring sedan with the exhilarating performance of a sports car. As we celebrate the 30th anniversary of this automotive icon, now firmly established as a classic, we delve into the captivating story of its creation, guided by two key figures from its development team at Porsche.
Michael Hölscher, Project Manager Development, and Michael Mönig, from Prototype Management, hadn’t been behind the wheel of the 500 E in nearly three decades. To commemorate the anniversary, they embarked on a 100-kilometer journey through Zuffenhausen, Weissach, and Sindelfingen, retracing the car’s development journey. Their expedition started and concluded at the Porsche Museum, where a Sapphire Black Metallic (color code 009) 500 E awaited them, its reflection shimmering in the museum’s mirrored ceiling. The interior, a blend of leather, wood, vibrant door panels, electrically adjustable sports seats, and a classic cassette radio, transported them back in time.
“Looking at the Mercedes-Benz 500 E today, it’s almost unbelievable that such a perfect design could emerge 30 years ago without the aid of CAD data. I have immense respect for the vision of my colleagues in the body shop,” remarks Hölscher, as he examines the saloon with the fondness of reuniting with an old friend. Both he and Mönig meticulously inspect the car, particularly admiring the pronounced fenders – a distinctive feature that set the 500 E apart from the standard production models of the Mercedes-Benz W124 series.
The story of the Mercedes-Benz 500 E began in 1988 when Daimler-Benz AG in Untertürkheim, Stuttgart, contracted Porsche AG for the development. The technical brief outlined the “design and experimental series development of the base type W124.” The crucial element was the integration of the potent five-liter V8 four-valve engine from the Mercedes-Benz 500 SL. Between 1990 and April 1995, a total of 10,479 units of the 500 E were produced. Notably, all were four-seaters due to the size of the differential, which precluded the inclusion of seat suspension in the center of the rear bench.
The Mercedes-Benz 500 E: A Superior Grand Tourer
The Mercedes-Benz 500 E remains etched in the memories of Hölscher and Mönig. “Thirty years ago, I drove to Lake Constance with three colleagues in the 500 E. We were engrossed in conversation throughout the journey. Suddenly, one of them glanced at the speedometer and was astonished to see it registering 250 km/h. We had meticulously fine-tuned the chassis, brakes, and engine to create an unparalleled driving experience,” Hölscher recalls. Braking performance was a significant point of discussion during development. The team ultimately decided on more robust brakes than those of the standard W124 to ensure optimal brake balance for the high-performance sedan.
Equipped with a standard four-speed automatic gearbox, the Mercedes-Benz 500 E, depending on the model year, could accelerate from 0 to 100 km/h in a mere 6.1 seconds. It boasted an impressive 326 PS (240 kW) power output and a maximum torque of 480 newton meters. The top speed was electronically limited to 250 km/h. “It offered abundant power without being overtly flashy, embodying both dynamism and luxury. The 500 E is not a showy car. It represents pure understatement, only capturing attention upon closer inspection,” Mönig explains, highlighting the flagship model’s ethos. Their journey then led them to the second stop – the former Reutter building, located a short distance from the Porsche Museum.
Assembly at the Reutter Building: A Porsche-Mercedes Partnership
“This order was crucial for us, ensuring optimal capacity utilization in Zuffenhausen and Weissach,” Hölscher recounts, leaning against the brick wall of the former Reutter building. From 1990 onwards, the Mercedes-Benz 500 E bodies were manufactured within these walls, in the Reutter building of Werk 2 in Zuffenhausen. This facility was vacant at the time and provided ample space to establish a dedicated body assembly line for the 500 E.
The production process was meticulously orchestrated. Mercedes-Benz delivered body parts from Sindelfingen to Zuffenhausen. At Werk 2, the Porsche team assembled the bodies using these components and parts manufactured in-house, including the distinctive front fenders. The assembled bodies were then transported back to Sindelfingen for painting. Following painting, the cars returned to the Rössle Bau in Zuffenhausen for final assembly and engine installation. The entire production cycle spanned 18 days, with each 500 E making two round trips between Zuffenhausen and Sindelfingen. “Logistically, shuttling vehicle parts back and forth was a significant undertaking. Ensuring that the correct parts arrived at the right location at the precise moment was a constant challenge,” Hölscher explains.
Project 500 E: Launched Amidst a Crisis
The collaboration between Mercedes-Benz and Porsche proved to be remarkably timely. Porsche was grappling with a crisis, facing declining export revenues, reduced production, and a string of negative key performance indicators. “One crucial lesson from the 500 E project during those turbulent times was the importance of embracing every challenge. Orders like this enabled us to retain our skilled team,” recalls Hölscher, who dedicated his career to Porsche from 1982 until his retirement in 2016. Initially, production commenced at ten vehicles per day, but strong demand quickly prompted an increase to 20 units daily. “Here we stand at counting point 0, the birthplace of the 500 E,” Mönig states. Installation of the chassis, gearbox, and engine – the ‘marriage’ – occurred at point 4, while counting point 8 marked the completion and delivery stage.
Witnessing the Mercedes-Benz 500 E enter series production was a defining moment for both men. Returning to the former Reutter building evokes powerful memories. Hölscher reflects, “The 500 E was the first project I spearheaded that reached series production. Three decades later, it feels as if I’m watching the vehicles roll off the production line once again.” He also fondly remembers the autonomy his team enjoyed during the project. Beyond their shared passion for cars and motorcycles, what binds Hölscher and Mönig? “We first met through the 500 E project and subsequently collaborated on numerous other ventures. It was a significant and deeply important chapter in my life,” Hölscher concludes.
The Astonishing Performance of a Timeless Classic
In the late 1980s, Daimler-Benz AG sought Porsche’s expertise as a development service provider because their own production capacity for the W124 series in Sindelfingen was insufficient. The wider body of the 500 E, later renamed the Mercedes-Benz E 500 as part of a model update, made in-house production impractical. Modifying their existing production line wasn’t financially viable for the limited production run. The objective was to create a car that appeared as a standard W124 at first glance, yet set unprecedented benchmarks – a high-performance saloon unlike anything seen before, designed for discerning enthusiasts. The 500 E was 56 millimeters wider and 23 mm lower than the base W124. Within Porsche, the project was internally designated “Project 2758”.
Mönig, who has been with Porsche for over 35 years and spearheaded the prototype construction of the 500 E, takes the driver’s seat, but not before hearing Hölscher’s impressions from behind the wheel: “Thirty years have passed, and the automotive industry has undergone immense changes, but even today, the 500 E holds its own. Its handling is superb. The acceleration is remarkable, the brakes are exceptional, and driving this car, with its dynamic character, is pure pleasure. I particularly appreciate the refined and understated sound of the eight-cylinder engine.”
Upon reaching the Weissach Development Centre, Hölscher parks in front of the hexagon, formerly the design engineering office and one of the first buildings at the site, marking the third stop on their nostalgic journey. “Being here feels like coming home,” he says, handing the keys to Mönig for the remainder of the drive.
Weissach: Where Innovation and Performance Took Shape
Weissach was the hub for Mönig’s team’s development work on the Mercedes-Benz 500 E throughout the late 1980s. He and his colleagues manually converted the first 14 base vehicles there. From the 15th vehicle onwards, assembly shifted to Building 1, the prototype construction building at the time, utilizing newly designed body shell components and modified series parts. The production of these demonstration vehicles played a crucial role in Mercedes-Benz’s decision to proceed with series production. “We orchestrated the development of the 500 E here in Weissach and worked tirelessly to accommodate the large V8 engine within the relatively compact W124 chassis,” recounts Hölscher. To optimize weight distribution, the battery was relocated from the engine compartment to the rear right of the luggage compartment. The brake and exhaust systems underwent substantial modifications, and the fenders and bumper trim at the front and rear were redesigned. The eight-cylinder engine drew air through the space surrounding the two headlights, ensuring ample airflow. With a 90 percent development share, Porsche essentially spearheaded all aspects essential for integrating the powertrain and vehicle components.
The journey continued from Weissach to Sindelfingen, the fourth and final stop. Mönig, behind the wheel, is visibly moved. “The acceleration is breathtaking. I only have positive memories of this car, having been entrusted with significant responsibility as a young engineer. The 500 E was and remains my favorite project,” he affirms. Mönig passionately describes the feeling of lightness behind the wheel, the palpable power, and the overall superior driving sensation. He and his colleagues from Prototype Construction dedicated numerous weekends in Sindelfingen to the project. Their collective commitment was instrumental in overcoming delays in the tight project timeline. “The collaboration with our Mercedes-Benz counterparts was characterized by mutual respect, focus, and equality, driven by a shared desire for success,” he recalls. A particularly memorable moment for him was the first day driving to the Sindelfingen site with his colleagues and a multitude of prototype parts. “That was truly special.”
On the return journey to Zuffenhausen, Mönig simply savors the V8 engine’s note with the window slightly open. Later, back at the museum workshop, he will have ample opportunity to elaborate on the superior performance that continues to define the Mercedes-Benz 500 E, even three decades later. For now, he simply relishes the feeling of driving this automotive masterpiece.
