In 1990, the Paris Motor Show witnessed the unveiling of a vehicle that would soon become a legend – the Mercedes-Benz 500 E. Spring of 1991 marked its official market launch, a moment when the automotive world recognized a unique blend of luxurious touring comfort and exhilarating sports car performance. As this automotive icon celebrates its 30th anniversary, achieving coveted classic status, the Porsche Museum embarked on a journey. They invited two key figures from its development team to revisit the captivating story of its creation and lasting impact.
Michael Hölscher, Project Manager Development, and Michael Mönig, from Prototype Management, hadn’t experienced the 500 E from within for nearly three decades. Their commemorative journey covered a 100-kilometer route, weaving through Zuffenhausen, Weissach, and Sindelfingen. Starting and concluding at the Porsche Museum, the 500 E awaited them, its Sapphire Black Metallic (code 009) exterior reflecting in the museum’s mirrored ceiling. The interior revealed a classic blend of leather, wood, vibrant door panels, power-adjustable sports seats, and a nostalgic cassette radio.
“Looking at this benz 500 e today, it’s almost unbelievable that such a perfect design emerged 30 years ago without the aid of CAD data. My respect for the body shop colleagues and their visionary approach is immense,” remarked Hölscher, observing the saloon with the warmth of reconnecting with an old friend. Both he and Mönig keenly examined the pronounced wings – a defining characteristic distinguishing the 500 E from standard 124 series models.
A Unique Collaboration: Porsche’s Role in the 500 E Development
The story of the Mercedes-Benz 500 E is intrinsically linked to an unusual partnership. In 1988, Daimler-Benz AG, based in Untertürkheim, Stuttgart, contracted Porsche AG for the development of this high-performance saloon. The technical brief specified “design and experimental series development of the base type W124.” Crucially, it was to house the potent five-litre V8 four-valve engine adopted from the acclaimed 500 SL roadster. By April 1995, a total of 10,479 units were manufactured. All were configured as four-seaters, a consequence of the substantial size of the differential, which occupied the space normally reserved for center seat suspension in the rear. This detail underscores the engineering challenges overcome to integrate such a powerful drivetrain into the W124 chassis.
Superior Touring and Thrilling Performance
The 500 E remains etched in the memories of Hölscher and Mönig as an exceptional vehicle. Hölscher recounts, “Thirty years ago, I drove to Lake Constance with three colleagues in the 500 E. We spent the entire journey in conversation, completely unaware of the speed. Suddenly, one of them glanced at the speedometer and was shocked to see it registering 250 km/h. We had meticulously fine-tuned the chassis, brakes, and engine to create a truly exceptional driving experience.” Brake development was a significant point of discussion during the prototype phase. To ensure optimal braking performance, the team opted for more robust brakes than those fitted to the standard W124.
Equipped with a standard four-speed automatic gearbox, the 500 E delivered breathtaking performance figures for its time. Depending on the model year, it could accelerate from 0 to 100 km/h in a mere 6.1 seconds, propelled by its 326 PS (240 kW) power output and a substantial 480 newton metres of torque. The top speed was electronically governed at 250 km/h. Mönig describes the car as, “Plenty of power, yet understated, simultaneously dynamic and luxurious. The 500 E is not overtly showy. It embodies pure understatement, revealing its special nature only upon closer inspection.” With the former Reutter building, located near the Porsche Museum, as their next destination, Mönig and Hölscher continued their journey, tracing the 500 E’s origins.
The Reutter Building: Birthplace of the 500 E Body
“This order was crucial for us, ensuring optimal capacity utilization in both Zuffenhausen and Weissach,” Hölscher recalled, leaning against the brick wall of the Reutter building. From 1990, this very building, within Werk 2 in Zuffenhausen, became the production site for the 500 E bodies. The Reutter building, then vacant, offered ample space for establishing a dedicated body assembly line for this special project.
The production process was meticulously orchestrated. Mercedes-Benz supplied body panels from Sindelfingen to Zuffenhausen. At Werk 2, the Porsche team assembled the bodies, incorporating both Mercedes-supplied components and Porsche-manufactured parts, including the distinctive front wings. These bodies were then transported back to Sindelfingen for painting. Following painting, the cars returned to the Rössle Bau in Zuffenhausen for final assembly, including engine installation. The entire production cycle spanned 18 days, with each 500 E making a round trip between Zuffenhausen and Sindelfingen. “Logistically, managing the back-and-forth transport of vehicle parts was a significant undertaking. Ensuring parts arrived at the correct location at the precise time was essential,” explained Hölscher.
Project Launch Amidst a Crisis
The timing of this collaboration between the two Stuttgart automotive giants proved remarkably opportune. Porsche was navigating a challenging period, facing declining export revenues, production decreases, and concerning key performance indicators. “One crucial lesson from the 500 E project during those difficult times was the importance of embracing every challenge. Orders like this enabled us to retain our skilled team,” recalled Hölscher, who dedicated his career to Porsche from 1982 until his retirement in 2016. Initially, production commenced at ten vehicles per day. However, driven by strong demand, production was quickly increased to 20 units daily. “This spot marks counting point 0, the very birthplace of the 500 E,” Mönig pointed out. The crucial “marriage” – the installation of the chassis, gearbox, and engine – occurred at counting point 4, while counting point 8 signified vehicle delivery.
Witnessing the 500 E transition into series production was a career highlight for both men. Revisiting the former Reutter building evoked strong memories. Hölscher reflected, “The 500 E was the first series production project I was entrusted with. Three decades later, it feels like I’m watching the cars roll off the line again.” He also fondly recalled the considerable autonomy his team enjoyed during the project. Beyond their shared passion for cars and motorbikes, what bonds him and Mönig? “We connected through the 500 E project and subsequently collaborated on several other ventures. It was a significant and formative period in my career,” Hölscher affirmed.
Astonishing Performance and Lasting Legacy
In the late 1980s, Daimler-Benz AG sought Porsche’s expertise as a development service provider because their own production facilities for the 124 series in Sindelfingen lacked the capacity for the wider-bodied 500 E. Later rebranded as the E 500 as part of a model update, the 500 E’s broader dimensions made in-house production impractical. Modifying their existing production line was deemed uneconomical. The objective was for the 500 E to maintain the visual identity of the W124 at first glance, while simultaneously establishing unprecedented performance benchmarks – a high-performance saloon unlike any seen before, reserved for discerning enthusiasts. It was 56 millimetres wider and 23 mm lower than the standard W124. Within Porsche, the 500 E was internally designated “Project 2758”.
Mönig, a Porsche veteran of over 35 years, who spearheaded the 500 E prototype construction, took the driver’s seat. However, he first sought Hölscher’s contemporary driving impressions: “Even today, 30 years on, the 500 E remains incredibly impressive. Its handling is superb. Longitudinal acceleration is outstanding, the brakes are exceptional, and driving it is pure pleasure thanks to its dynamic character. And I particularly appreciate the refined, understated sound of that eight-cylinder engine.”
Upon reaching the Weissach Development Centre, Hölscher parked in front of the “hexagon,” the former design engineering office, one of the site’s original buildings and their third stop. “Being here feels like returning home,” he said, handing the keys to Mönig for the remainder of their journey.
Engineering Excellence: Modified Headlights and Porsche’s Development Prowess
Weissach was the epicenter of the 500 E development in the late 1980s. Mönig’s team manually converted the first 14 base vehicles there. From the 15th vehicle onwards, assembly shifted to Building 1, the prototype construction facility at the time, utilizing newly designed body shell components and modified series parts. The production of these demonstration vehicles was instrumental in Mercedes-Benz’s decision to proceed with series production. “We planned the 500 E’s development here, diligently working to accommodate the large engine within the relatively compact vehicle,” recounted Hölscher. To optimize weight distribution, the battery was relocated from the engine bay to the rear luggage compartment’s right side. Significant revisions were made to the brake and exhaust systems, while the wings and bumper trim were redesigned front and rear. Notably, the eight-cylinder engine drew air through the gaps surrounding the headlights, ensuring ample intake. Porsche undertook approximately 90 percent of the development work, encompassing virtually all integration aspects of the powertrain and vehicle components.
The journey continued from Weissach to Sindelfingen, their fourth stop. Mönig, behind the wheel, expressed his enthusiasm. “The longitudinal dynamics are simply spectacular. I hold only positive memories of this vehicle, particularly as I was entrusted with considerable responsibility as a young engineer. The 500 E was, and remains, my favorite project,” he concluded. Mönig passionately described the sensation of lightness, the palpable power, and the superior driving feel. He and his Prototype Construction colleagues dedicated numerous weekends in Sindelfingen to the project. Their collective dedication was crucial in mitigating delays within the tight project timeline. “The collaboration with our Mercedes-Benz counterparts was characterized by mutual respect, focus, equality, and a shared drive for success,” he recalled. A defining moment for him was their initial trip to the Sindelfingen site, accompanied by numerous prototype parts. “That was truly special.”
On their return journey to Zuffenhausen, Mönig simply savored the V8 engine’s sound with the window slightly open. Later, after parking the 500 E back in the museum workshop, he would elaborate further on the enduring superior performance that continues to distinguish the 500 E, three decades later. For now, he simply relished the driving experience.
