The Mercedes-Benz 500 E, a vehicle that debuted to public acclaim at the 1990 Paris Motor Show, marked its entry into the market in the spring of 1991. This model masterfully blended the luxurious comfort expected of a touring saloon with the exhilarating performance typically associated with sports cars. As we celebrate the 30th anniversary of this automotive icon – a milestone that also signifies its esteemed classic status – the Porsche Museum embarked on a unique journey. They invited two key figures from the 500 E’s development team to retrace the fascinating story of its creation.
Michael Hölscher, Project Manager Development, and Michael Mönig, Prototype Management, hadn’t been behind the wheel of a 500 E for nearly three decades. Their commemorative drive, a 100-kilometer loop, encompassed significant locations like Zuffenhausen, Weissach, and Sindelfingen, each playing a crucial role in the car’s history. Starting and concluding at the Porsche Museum, the 500 E awaited them, its Sapphire Black Metallic (paint code 009) exterior reflecting in the museum’s mirrored ceiling. The interior showcased a blend of luxury and sportiness, featuring leather, wood trim, vibrant door panels, electrically adjustable sports seats, and a classic cassette radio.
“Looking at the car today, it’s almost unbelievable that such a perfect design could emerge 30 years ago without the aid of CAD data. My respect for the body shop colleagues and their visionary approach is immense,” remarked Hölscher, examining the saloon with the fondness of reuniting with an old friend. Both Hölscher and Mönig meticulously inspected the car, particularly noting the pronounced wings – a distinctive feature that set the 500 E apart from the standard Mercedes-Benz W124 series models.
The genesis of the Mercedes-Benz 500 E dates back to 1988 when Porsche AG secured a development contract from Daimler-Benz AG in Untertürkheim. The technical brief outlined the “design and experimental series development of the base type W124.” A key requirement was the integration of the potent five-litre V8 four-valve engine from the Mercedes-Benz 500 SL. Production spanned until April 1995, culminating in 10,479 units, all configured as four-seaters. This limitation arose from the substantial size of the differential, which precluded space for seat suspension in the rear center bench.
The Mercedes 500 E: A Superior Touring Experience
Both Hölscher and Mönig retain vivid and fond memories of the 500 E. Hölscher reminisced, “Thirty years ago, I drove to Lake Constance with three colleagues. We spent the entire journey engaged in conversation, such was the car’s effortless cruising ability. At one point, one of my colleagues glanced at the speedometer and was taken aback to see the needle pointing at 250 km/h. We had meticulously fine-tuned the chassis, brakes, and engine, guaranteeing a truly exceptional driving experience.” Brake system development was a particularly debated topic during the prototype phase. The team ultimately decided on more robust brakes than those on the standard W124 to ensure optimal braking performance for the powerful 500 E.
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 power output of 326 PS (240 kW) and a peak torque of 480 newton metres. The top speed was electronically governed at 250 km/h. Mönig described the 500 E as, “Plenty of power, yet remarkably understated, simultaneously dynamic and luxurious. The 500 E isn’t a flashy car; it embodies pure understatement, only truly revealing its special nature upon closer inspection.” From the Porsche Museum, their journey continued to the second stop – the former Reutter building, located a short distance away.
Assembly at the Reutter Building: A Porsche-Mercedes Collaboration
“This order was crucial for us, ensuring efficient capacity utilization in Zuffenhausen and Weissach,” Hölscher recalled, leaning against the brickwork of the former Reutter building. From 1990, the 500 E bodies were manufactured within these walls, in Werk 2 of Zuffenhausen. This facility, then vacant, provided ample space for a dedicated 500 E body assembly line.
The production process was meticulously orchestrated. Mercedes-Benz supplied body panels from Sindelfingen to Zuffenhausen. At Werk 2, the Porsche team assembled the bodies using these components along with in-house manufactured parts, notably the distinctive front wings. The assembled bodies were then transported back to Sindelfingen for painting. Subsequently, the cars returned to Zuffenhausen’s Rössle Bau for final assembly, including engine installation. Each Mercedes-Benz 500 E underwent an 18-day production cycle and traversed the route between Zuffenhausen and Sindelfingen twice. “Logistically, transporting parts back and forth presented a significant challenge. Ensuring parts arrived at the correct location precisely when needed was paramount,” Hölscher explained.
Project Launch Amidst Porsche’s Challenges
The collaboration between Mercedes-Benz and Porsche emerged at an opportune moment. Porsche was navigating a period of crisis, marked by declining export revenues, reduced production volume, and generally unfavorable key performance indicators. “One crucial lesson from the 500 E project during those challenging times was the importance of embracing every opportunity. Projects 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, strong demand quickly led to an increase to 20 vehicles daily. “Here we stand at counting point 0, the birthplace of the 500 E,” Mönig stated, indicating their location within the former Reutter building. The ‘marriage’ – the installation of the chassis, gearbox, and engine – occurred at point 4, while point 8 marked vehicle delivery.
Witnessing the 500 E enter series production was a career highlight for both men. Revisiting the former Reutter building evoked strong emotions. Hölscher shared, “The 500 E was the first project I spearheaded that reached series production. Three decades later, it feels like I’m watching the cars roll off the line again.” He also fondly recalled the autonomy his team enjoyed during development. Beyond their shared passion for cars and motorcycles, Hölscher reflected on his bond with Mönig, “We connected through the 500 E project and subsequently collaborated on numerous other ventures. It was a significant and formative period in my professional life.”
The Astonishing Performance of a Legend
In the late 1980s, Daimler-Benz AG entrusted Porsche with the 500 E development due to capacity constraints on their own W124 series production line in Sindelfingen. The 500 E’s wider body, which later led to its renaming as the E 500 during a model update, exceeded the production capabilities of Mercedes-Benz’s existing facilities. Re-tooling the production line was deemed uneconomical for the relatively limited production run. The objective was for the 500 E to maintain the visual identity of the W124 while establishing unprecedented standards as a high-performance saloon. It was 56 millimetres wider and 23 mm lower than the standard W124. Internally at Porsche, the 500 E project was codenamed “Project 2758”.
Mönig, a Porsche veteran of over 35 years and responsible for building the 500 E prototype, took the driver’s seat. Before setting off, he listened to Hölscher’s driving impressions: “Even after thirty years and the immense advancements in the automotive industry, the 500 E remains remarkably relevant. Its handling is superb. The acceleration is phenomenal, the brakes are exceptional, and the dynamic character makes it an absolute pleasure to drive. And I particularly appreciate the refined, yet powerful sound of the eight-cylinder engine.”
Upon reaching the Weissach Development Centre, Hölscher parked in front of the ‘hexagon’, formerly the design engineering office and one of the site’s original buildings, marking the third stop on their journey. “Being here feels like returning home,” he expressed, handing the keys to Mönig for the remainder of the drive.
Weissach: The Heart of 500 E Development
Weissach served as the hub for Mönig’s team’s 500 E development work in the late 1980s. His team manually converted the initial 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 played a pivotal role in Mercedes-Benz’s decision to proceed with series production. “We spearheaded the 500 E development planning here in Weissach and worked tirelessly to integrate the large V8 engine into the relatively compact W124 chassis,” Hölscher recounted. To optimize weight distribution, the battery was relocated from the engine compartment to the rear luggage area. Significant modifications were made to the brake and exhaust systems, and the front and rear wings and bumper trim were redesigned. The eight-cylinder engine drew air through the spaces surrounding the headlights, ensuring ample intake. Porsche assumed responsibility for approximately 90 per cent of the development effort, encompassing virtually all aspects of drive and vehicle component integration.
From Weissach, the journey continued to Sindelfingen, the fourth and final stop. Mönig, behind the wheel, appeared deeply impressed. “The acceleration is breathtaking. I cherish positive memories of this car, having been 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 dynamics. He and his Prototype Construction colleagues spent numerous weekends in Sindelfingen. Their collective dedication was instrumental in mitigating delays in the demanding project timeline. “The collaboration with our Mercedes-Benz counterparts was characterized by mutual respect, focus, equality, and a shared ambition for success,” he recalled. A particularly memorable moment for him was the initial trip to the Sindelfingen site with his team and a truckload of prototype components. “That was truly special.”
On the 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 have ample opportunity to discuss the superior performance that continues to distinguish the Mercedes-Benz 500 E, even three decades later. For now, he simply relished the sensation of driving this automotive legend.
