The Mercedes-Benz 500 E, a vehicle that debuted to public acclaim at the 1990 Paris Motor Show and subsequently went on sale in the spring of 1991, masterfully blended the comfort expected of a luxury saloon with the exhilarating performance typically associated with sports cars. As this iconic model marked its 30th anniversary – achieving undisputed classic status – the Porsche Museum embarked on a mission to uncover the captivating narrative behind its creation. They dispatched two key figures from the development team on a journey to retrace the steps and rediscover the exciting story of how this remarkable car came to be, a testament to the unique partnership between Porsche Mercedes.
Michael Hölscher, the Project Manager for Development, and Michael Mönig, from Prototype Management, had last experienced the 500 E nearly three decades prior. Now, their journey encompassed a 100-kilometer route, taking them through Zuffenhausen, Weissach, and Sindelfingen. Starting and concluding at the Porsche Museum, the 500 E awaited them, its Sapphire Black Metallic exterior (colour code 009) gleaming under the mirrored museum ceiling. Inside, a luxurious blend of leather, wood, vibrant door trims, electrically adjustable sports seats, and a classic cassette radio evoked the era.
“Looking at this car today, it’s almost unbelievable that such a perfect design could emerge 30 years ago without CAD data. I have immense respect for the vision of my colleagues, especially in the body shop,” remarked Hölscher, observing the saloon with the affection of an old friend. Both he and Mönig meticulously examined the car, particularly admiring the pronounced wings – a distinctive feature setting the 500 E apart from the standard 124 series Mercedes-Benz models. These subtle yet significant design cues hinted at the powerful Porsche Mercedes engineering beneath.
In 1988, Daimler-Benz AG in Untertürkheim, Stuttgart, awarded Porsche AG the development contract. The technical specifications outlined the “design and experimental series development of the base type W124”. Crucially, the vehicle was slated to house the potent five-litre V8 four-valve engine from the 500 SL. By April 1995, a total of 10,479 units had been manufactured. Notably, all were four-seaters, a consequence of the substantial size of the differential, which precluded space for seat suspension in the rear bench’s middle. This detail underscores the engineering challenges overcome through the Porsche Mercedes collaboration.
The Superior Touring Car: A Blend of Power and Refinement
Both Hölscher and Mönig retain fond memories of the 500 E. “Thirty years ago, I drove to Lake Constance with three colleagues. We talked non-stop throughout the journey. At one point, one of them glanced at the speedometer and was quite shocked to see it reading 250 km/h. We had meticulously tuned the chassis, brakes, and engine to ensure an exceptional driving experience,” Hölscher reminisced. Discussions around the brakes were particularly extensive during development, with the team ultimately opting for more robust brakes than the base vehicle to guarantee optimal brake balance. This dedication to performance enhancement is a hallmark of the Porsche Mercedes project.
Equipped with a standard four-speed automatic gearbox, the 500 E, depending on the model year, could accelerate from 0 to 100 km/h in a mere 6.1 seconds, boasting 326 PS (240 kW) and a peak torque of 480 newton metres. Its top speed was electronically limited to 250 km/h. “It offered ample power, yet remained understated, both dynamic and luxurious simultaneously. The 500 E isn’t flashy; it embodies pure understatement, only catching attention upon closer inspection,” Mönig described the series’ flagship model. He and Hölscher then proceeded to their second stop – the former Reutter building, located near the Porsche Museum, a site integral to the Porsche Mercedes story.
The Reutter Building: Assembly Line for a Legend
“This order was crucial for us, ensuring optimal capacity utilization in Zuffenhausen and Weissach,” Hölscher recalled, leaning against the brick wall of the former Reutter building. From 1990 onwards, the 500 E bodies were manufactured within these walls, in Werk 2’s Reutter building in Zuffenhausen. This building, then vacant, provided ample space for a dedicated body assembly line for the 500 E. This strategic move highlighted the resourcefulness of the Porsche Mercedes collaboration.
The production process was meticulously defined. Mercedes-Benz supplied body parts from Sindelfingen to Zuffenhausen. At Werk 2, the Porsche team assembled the body using these components and in-house manufactured parts, including the distinctive front wings. The assembled bodies were then returned to Sindelfingen for painting. Following this, the cars were completed in the Rössle Bau in Zuffenhausen, where final assembly and engine installation took place. The entire production cycle spanned 18 days, with each 500 E making two journeys between Zuffenhausen and Sindelfingen. “Logistically, shuttling vehicle parts back and forth was a significant undertaking. Ensuring parts arrived at the correct location at the right time was critical,” Hölscher explained. This complex logistical dance showcased the coordinated efforts of Porsche Mercedes.
Project Launch Amidst Crisis: A Turning Point for Porsche
The timing of this collaboration between the two Stuttgart-based automotive giants proved remarkably opportune. Porsche faced a crisis, grappling with declining export revenues, reduced production, and largely negative key performance indicators. “One key takeaway from this project during those challenging times was the importance of embracing every challenge. Orders like these allowed us to retain our team,” Hölscher reflected, who was with Porsche from 1982 until his early retirement in 2016. Initially, production started at ten vehicles per day, but demand quickly prompted an increase to 20 units daily. “Here we are at counting point 0, the birthplace of the 500 E,” Mönig noted. Installation of the chassis, gearbox, and engine – the ‘marriage’ – occurred at point 4, while point 8 marked delivery. This efficient production line was a testament to the Porsche Mercedes partnership’s success.
Witnessing the vehicle enter series production was a highlight for both men. Visiting the former Reutter building evoked strong memories for Hölscher: “The 500 E was the first series production project I oversaw. Three decades later, it feels like watching the vehicles roll off the line again.” He also fondly recalled the autonomy his team enjoyed. Beyond their shared passion for cars and motorbikes, Hölscher reflected on his bond with Mönig, “We met through the 500 E project and subsequently managed several others together. It was a significant and important period in my life.” This shared experience cemented the legacy of the Porsche Mercedes project in their careers.
Astonishing Performance: Setting New Standards
In the late 1980s, Daimler-Benz AG commissioned Porsche as a development service provider because their own Sindelfingen production line for the 124 series was inadequate. The 500 E’s wider body, later renamed E 500 during a model update, exceeded Sindelfingen’s production capabilities. Modifying their equipment wasn’t financially viable. The goal was for the 500 E to initially resemble a standard W124, yet establish unprecedented performance benchmarks – a high-performance saloon unlike any seen before, specifically for discerning enthusiasts. It was 56 millimetres wider and 23 mm lower than the base vehicle. Internally at Porsche, the 500 E was designated “Project 2758”. This ambitious project truly showcased the Porsche Mercedes engineering prowess.
Mönig, with over 35 years at Porsche and responsible for building the 500 E prototype, took the driver’s seat, first listening to Hölscher’s 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 it’s a joy to drive with its dynamic character. I particularly appreciate the beautiful, understated sound of the eight-cylinder engine.” The enduring performance is a testament to the Porsche Mercedes engineering.
Upon reaching the Weissach Development Centre, Hölscher parked in front of the former design engineering office, the hexagon building – an early structure at the site and their third stop. “Being here feels like coming home,” he said, handing the keys to Mönig for the remainder of their journey. Weissach was the heart of Porsche Mercedes development for this project.
Modified Headlights: An Ingenious Design Solution
Weissach was where Mönig’s team conducted all 500 E development in the late 1980s. They manually converted the first 14 base vehicles. From the 15th onward, assembly transitioned to Building 1, the prototype construction building, utilizing newly designed bodyshell parts and modified series components. Demonstration vehicle production convinced Mercedes-Benz to proceed with series production. “We planned the 500 E’s development here, working diligently to integrate the large engine into the relatively compact vehicle,” Hölscher recounted. To optimize weight distribution, the battery was relocated from the engine compartment to the rear luggage compartment’s right side. The brake and exhaust systems underwent significant modifications, and the front and rear wings and bumper trim were redesigned. The eight-cylinder engine drew air through the gap surrounding the headlights for ample intake. With a 90 percent development share, Porsche effectively managed almost all aspects required for integrating the powertrain and vehicle components. This intricate engineering is a hallmark of the Porsche Mercedes collaboration.
The journey continued from Weissach to Sindelfingen, their fourth stop. Mönig, behind the wheel, appeared deeply moved. “The longitudinal dynamics are incredible. I have only positive memories of this vehicle, having been given significant responsibility as a young engineer. The 500 E was and remains my favorite project,” he concluded. Mönig spoke passionately about the feeling of lightness, the palpable power, and the superior driving experience. He and his Prototype Construction colleagues spent numerous weekends in Sindelfingen. Their dedication helped recover lost time in the tight project schedule. “The collaboration with Mercedes-Benz colleagues was respectful, focused, equitable, and driven by a shared desire for success,” he remembered. A defining moment for him was the first day driving to Sindelfingen with colleagues and numerous prototype parts. “That was very special.” This successful collaboration is a shining example of Porsche Mercedes synergy.
On the return to Zuffenhausen, he simply listened to the V8 engine with the window slightly open. Later, after parking it in the museum workshop, he would have much to share about the superior performance that still defines the 500 E three decades later. But for now, he savored the driving experience, a tangible link to the remarkable Porsche Mercedes legacy.
