In the autumn of 1990, the Paris Motor Show witnessed the unveiling of a vehicle that would soon become a legend – the Mercedes-benz 500 E. Hitting the market in spring 1991, this sedan seamlessly blended the luxurious comfort expected of a touring car with the exhilarating performance of a sports car. As we celebrate its 30th anniversary and its undeniable classic status, the Porsche Museum dispatched two key figures from its development team on a nostalgic journey. Their mission: to rediscover and share the captivating story of the 500 E’s creation.
![Alt text: Michael Hölscher and Michael Mönig revisit the Mercedes-Benz 500 E, a testament to Porsche and Mercedes-Benz collaboration, at the Porsche Museum for its 30th anniversary.]
Michael Hölscher, the Project Manager for Development, and Michael Mönig, from Prototype Management, hadn’t been behind the wheel of a 500 E in nearly three decades. Their journey, a 100-kilometer loop, was designed to retrace the car’s origins, passing through Zuffenhausen, Weissach, and Sindelfingen. Starting and ending at the Porsche Museum, the 500 E awaited them, its Sapphire Black Metallic (code 009) exterior reflecting in the museum’s mirrored ceiling. Stepping inside revealed a classic Mercedes-Benz interior: leather, wood trim, vibrant door panels, electrically adjustable sports seats, and a period-correct cassette radio.
“Looking at this car now, 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, admiring the saloon with the fondness of seeing an old friend. Both men were captivated by the pronounced fenders, a key visual differentiator setting the 500 E apart from other models in the W124 series. These widened fenders hinted at the potent performance lurking beneath its sophisticated skin.
![Alt text: Front view of the Mercedes-Benz 500 E highlighting its iconic design and wider fenders, a signature of the high-performance sedan.]
The genesis of this remarkable vehicle dates back to 1988 when Daimler-Benz AG, based in Untertürkheim, commissioned Porsche AG for a significant development contract. The technical brief outlined the “design and experimental series development of the base type W124.” The ambitious goal was to integrate the powerful five-liter V8, four-valve engine from the Mercedes-Benz 500 SL into the W124 chassis. By April 1995, a total of 10,479 units of the 500 E were produced. Notably, all were four-seaters; the substantial size of the differential precluded the possibility of a center seat in the rear.
The Quintessential High-Performance Touring Sedan
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 a 500 E. We spent the entire journey in conversation, effortlessly cruising at high speed. At one point, a colleague glanced at the speedometer and was shocked to see we were doing 250 km/h. The chassis, brakes, and engine were so perfectly balanced, ensuring an exceptional driving experience,” Hölscher reminisced. Braking performance was a crucial point of discussion during development. The team ultimately decided on more robust brakes than the standard W124 to guarantee optimal stopping power for the increased performance.
![Alt text: Michael Hölscher and Michael Mönig standing beside the Mercedes-Benz 500 E, reflecting on their collaborative journey and the car’s enduring appeal.]
Equipped with a standard four-speed automatic transmission, the 500 E, depending on the model year, could accelerate from 0 to 100 km/h in a mere 6.1 seconds, boasting 326 horsepower (240 kW) and a peak torque of 480 Newton meters. Its top speed was electronically limited to 250 km/h. “It offered immense power, yet with remarkable understatement. Both dynamic and luxurious, the 500 E is not a flashy car. It embodies pure subtlety, revealing its true nature only upon closer inspection,” Mönig described the series’ flagship model. Their journey continued to the next significant location – the former Reutter building, a short distance from the Porsche Museum.
Assembly in the Reutter Building: A Unique Production Story
“This order was incredibly important for Porsche, ensuring optimal utilization of our capacities in Zuffenhausen and Weissach during a challenging period,” Hölscher recalled, leaning against the brick wall of the former Reutter building. Starting in 1990, the 500 E bodies were meticulously assembled within these walls, in the Werk 2 Reutter building in Zuffenhausen. This facility, then vacant, provided the necessary space for a dedicated 500 E body assembly line.
![Alt text: Close-up of the Mercedes-Benz 500 E’s widened rear fender, a testament to the body modifications performed by Porsche during its assembly.]
The production process was precisely orchestrated. Mercedes-Benz supplied body components from Sindelfingen to Zuffenhausen. At Werk 2, the Porsche team assembled the bodies, incorporating both Mercedes-Benz parts and in-house manufactured components, notably the distinctive front fenders. These bodies then returned to Sindelfingen for painting. Final assembly, including engine installation, occurred back in Zuffenhausen at the Rössle Bau facility. Each 500 E underwent an 18-day production cycle, making two round trips between Zuffenhausen and Sindelfingen. “Logistically, coordinating the back-and-forth movement of parts was a significant undertaking. Ensuring that the right components arrived at the right place, at the right time, was crucial,” Hölscher explained.
Project Launch Amidst Economic Challenges
The timing of this collaboration between the two Stuttgart automotive giants was particularly fortuitous. Porsche was navigating a period of crisis, facing declining export revenues, reduced production, and concerning key performance indicators. “One crucial lesson from the 500 E project during those challenging times was the importance of embracing every opportunity. Orders like this allowed us to retain our skilled team,” Hölscher, who was with Porsche from 1982 to 2016, reflected. Initially, production began at ten vehicles per day, but strong demand quickly led to an increase to 20 units daily. “This location, counting point 0, is the birthplace of the 500 E,” Mönig stated, highlighting the historical significance of the Reutter building. The integration of the chassis, gearbox, and engine – the ‘marriage’ – took place at counting point 4, and delivery occurred at counting point 8.
![Alt text: Interior detail of the Mercedes-Benz 500 E showcasing the classic design elements, including wood trim and leather upholstery, reflecting its luxury touring car heritage.]
Witnessing the 500 E enter series production was a career highlight for both men. Their return to the former Reutter building evoked powerful memories. Hölscher shared, “The 500 E was the first project I oversaw 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 and trust given to his team. Beyond their shared passion for cars and motorcycles, the 500 E project forged a lasting bond between Hölscher and Mönig. “We met through the 500 E and subsequently collaborated on numerous projects. It was a significant and formative part of my professional life,” Hölscher concluded.
Astonishing Performance and Lasting Legacy
In the late 1980s, Daimler-Benz AG turned to Porsche as a development partner because their own production facilities for the W124 series in Sindelfingen were not equipped for the 500 E’s wider body. Modifying the existing Sindelfingen line for the relatively low production volume of the 500 E was deemed impractical. The objective was to create a vehicle that appeared as a subtle evolution of the W124, yet delivered unprecedented performance. For discerning enthusiasts, it was to be a high-performance sedan unlike any other. It was 56 millimeters wider and 23 mm lower than the standard W124. Internally at Porsche, the 500 E was designated “Project 2758.”
Mönig, a Porsche veteran of over 35 years who spearheaded the 500 E prototype construction, took the driver’s seat. But first, he listened to Hölscher’s driving impressions: “Even today, 30 years later, the 500 E remains incredibly relevant. Its handling is superb. The acceleration is remarkable, the brakes are exceptional, and driving it is pure joy thanks to its dynamic character. And the understated growl of the eight-cylinder engine is simply delightful.”
![Alt text: Side profile of the Mercedes-Benz 500 E in motion, emphasizing its sleek lines and classic sedan silhouette.]
Arriving at the Weissach Development Centre, Hölscher parked in front of the “hexagon,” the original design engineering office building. This marked their third stop. “Being here feels like coming home,” he said, handing the keys to Mönig for the remainder of the journey.
Ingenious Engineering: Headlights and Air Intake
Weissach was the epicenter of the 500 E’s development in the late 1980s. Mönig and his team manually converted the first 14 base vehicles there. From the 15th vehicle onward, assembly shifted to Building 1, the prototype construction facility, utilizing newly designed body panels 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, focusing on the challenge of fitting 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. The brake and exhaust systems underwent significant modifications, and the front and rear fenders and bumper trim were redesigned. Intriguingly, the eight-cylinder engine drew its air supply through the gaps surrounding the two headlights, a clever engineering solution. With Porsche undertaking approximately 90 percent of the development work, their contribution was crucial for integrating the powertrain and vehicle components.
The journey continued from Weissach to Sindelfingen, their fourth stop. Mönig, behind the wheel, was clearly impressed. “The acceleration is truly spectacular. I have only positive memories of this car, particularly as I was entrusted with significant responsibility as a young engineer. The 500 E was and remains my favorite project,” he shared. Mönig passionately described the feeling of lightness and responsiveness, the powerful engine note, and the overall superior driving experience. He and his Prototype Construction team spent many weekends in Sindelfingen, their dedication contributing to overcoming delays in the demanding project timeline. “The collaboration with our Mercedes-Benz colleagues was respectful, focused, and equitable, driven by a shared desire for success,” he recalled. A defining moment for him was the initial trip to Sindelfingen with his team and numerous prototype parts. “That was truly special.”
![Alt text: Michael Mönig and Michael Hölscher in the Mercedes-Benz 500 E, symbolizing the successful partnership between Porsche and Mercedes-Benz in creating this automotive icon.]
On the return journey to Zuffenhausen, Mönig simply enjoyed the V8 engine’s sound with the window slightly open. Later, after parking the 500 E back in the museum workshop, he would have much more to say about the exceptional performance that continues to define the Mercedes-Benz 500 E, even three decades later. For now, he simply savored the drive.
