In the realm of automotive legends, certain vehicles transcend mere transportation, becoming symbols of innovation, performance, and collaboration. The Mercedes-Benz 500 E, born from an extraordinary partnership with Porsche, stands as a testament to this legacy. Unveiled to an awestruck audience at the 1990 Paris Motor Show, this remarkable saloon seamlessly fused the opulent comfort of a touring car with the exhilarating prowess of a sports car. As we celebrate its 30th anniversary and its undisputed classic status, we delve into the captivating story of its creation, guided by the very minds that brought this automotive icon to life.
Michael Hölscher, Project Manager Development, and Michael Mönig, from Prototype Management, recently reunited with the 500 E, a car they hadn’t encountered in nearly three decades. Their journey, a nostalgic 100-kilometer route encompassing Zuffenhausen, Weissach, and Sindelfingen, began and ended at the Porsche Museum. There, bathed in the reflections of the museum’s mirrored ceiling, stood the 500 E, a Sapphire Black Metallic (color code 009) beauty. The interior, a luxurious blend of leather, wood, vibrant door trims, electrically adjustable sports seats, and a classic cassette radio, evoked a sense of timeless elegance.
“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 in the body shop,” remarked Hölscher, his gaze lingering on the saloon with the fondness of an old friend. Both men, crouching down, admired the pronounced wings, a distinctive feature setting the 500 E apart from the standard 124 series models.
Porsche’s Crucial Role: Development and Production Partnership
The genesis of this remarkable vehicle traces back to 1988 when Daimler-Benz AG commissioned Porsche AG with a pivotal development contract. The technical specification was clear: “design and experimental series development of the base type W124”. At the heart of this project was the formidable five-liter V8 four-valve engine borrowed from the iconic 500 SL. Between 1990 and April 1995, a total of 10,479 units were meticulously crafted. Notably, every 500 E was designed as a four-seater, a consequence of the substantial size of the differential, which precluded space for seat suspension in the rear bench’s center. This collaboration marked a significant chapter in the Mercedes-Benz story, entrusting Porsche with the creation of a high-performance variant of their popular W124 series.
Design and Engineering Challenges
Hölscher and Mönig fondly recalled the 500 E’s exceptional touring capabilities. “Thirty years ago, I drove to Lake Constance with three colleagues. We talked the entire way. At one point, a colleague glanced at the speedometer and was shocked to see 250 km/h. The chassis, brakes, and engine were tuned to perfection, guaranteeing a superb driving experience,” Hölscher reminisced. The braking system was a subject of intense discussion during development. The team ultimately opted for more potent brakes than the base vehicle, ensuring optimal brake balance during the prototype phase.
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 meters. Its top speed was electronically governed at 250 km/h. “It offered ample power without being ostentatious, dynamic yet luxurious. The 500 E is understated, catching attention only upon closer inspection,” Mönig described the series’ flagship model. Their journey then led them to the former Reutter building, a stone’s throw from the Porsche Museum, marking the next chapter in the Mercedes 500 E story.
Innovative Production Process
“This order was crucial for maintaining capacity utilization in Zuffenhausen and Weissach,” Hölscher explained, leaning against the brick facade of the former Reutter building. From 1990 onwards, the 500 E bodies were meticulously assembled within these walls, in Werk 2 of Zuffenhausen. This building, then vacant, provided ample space for a dedicated body assembly line.
The production process was a carefully orchestrated dance. Mercedes-Benz supplied body parts from Sindelfingen to Zuffenhausen. At Werk 2, Porsche’s skilled team assembled the bodies, incorporating both supplied components and in-house manufactured parts, including the distinctive front wings. The bodies then embarked on a return journey to Sindelfingen for painting. Subsequently, the cars were transferred back to Zuffenhausen’s Rössle Bau for final assembly and engine installation. Each 500 E endured an 18-day production cycle, traversing the Zuffenhausen-Sindelfingen route twice. “Logistically, transporting parts back and forth was a significant challenge. Ensuring timely arrival of components was paramount,” Hölscher elaborated.
Project Launch in the Middle of a Crisis
The collaboration between these Stuttgart automotive giants occurred during a critical juncture for Porsche. Facing declining export revenues, reduced production, and unfavorable key performance indicators, the project arrived at an opportune moment. “A key lesson from this challenging period was to embrace every opportunity. Orders like these allowed us to retain our team,” Hölscher recalled, who dedicated his career to Porsche from 1982 to his early retirement in 2016. Initially, production commenced at ten vehicles per day, but surging demand quickly prompted an increase to 20 units daily. “This is counting point 0, the birthplace of the 500 E,” Mönig pointed out. The ‘marriage,’ the installation of the chassis, gearbox, and engine, took place at point 4, while delivery marked counting point 8.
Witnessing the 500 E enter series production was a career highlight for both men. Returning to the former Reutter building evoked powerful memories. Hölscher shared, “The 500 E was my first series production project as a project manager. Three decades later, it feels like watching the vehicles roll off the line again.” He fondly recalled the autonomy granted to his team, allowing them to work with initiative. Beyond their shared passion for cars and motorcycles, Hölscher reflected on his bond with Mönig: “We met through the 500 E and subsequently collaborated on numerous projects. It was a significant and formative period in my life.”
Astonishing Performance and Lasting Impression
In the late 1980s, Daimler-Benz AG sought Porsche’s expertise as a development service provider due to capacity constraints on their own 124 series production line in Sindelfingen. The 500 E’s wider body, later designated E 500 after a model update, rendered in-house production impractical. Modifying their existing equipment was deemed uneconomical. The objective was clear: the 500 E should initially resemble a standard W124 while establishing unprecedented performance benchmarks – a high-performance saloon unlike any seen before, designed for discerning enthusiasts. It was 56 millimeters wider and 23 mm lower than the base vehicle. Internally, Porsche designated the 500 E as “Project 2758”.
Mönig, a Porsche veteran of over 35 years, who oversaw the 500 E prototype construction, took the driver’s seat, after listening to Hölscher’s driving impressions: “Even today, 30 years later, the 500 E is exceptional. Its handling is superb. Longitudinal acceleration is outstanding, the brakes are phenomenal, and the dynamic character makes it a joy to drive. I particularly appreciate the refined and understated sound of the eight-cylinder engine.”
Arriving at the Weissach Development Centre, Hölscher parked before the hexagon, the former design engineering office and one of the site’s original buildings, marking the third stop. “Being here feels like returning home,” he said, handing the keys to Mönig for the remainder of the journey.
Modified Headlights for Drawing in Air
Weissach was the epicenter of the 500 E’s development in the late 1980s, where Mönig’s team meticulously converted the first 14 base vehicles by hand. From the 15th vehicle onward, assembly shifted to Building 1, the prototype construction facility, utilizing newly designed 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 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. 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 ingeniously drew air through the gap surrounding the headlights, ensuring ample intake. With a 90 percent development contribution, Porsche essentially spearheaded all aspects of integrating the powertrain and vehicle components.
The journey continued from Weissach to Sindelfingen, the fourth stop. Mönig, behind the wheel, expressed his exhilaration. “The longitudinal dynamics are spectacular. I have only positive memories of this vehicle, as I was entrusted with significant responsibility as a young engineer. The 500 E was and remains my favorite project,” he affirmed. Mönig passionately described the feeling of lightness, the palpable power, and the superior driving sensation. He and his Prototype Construction colleagues spent numerous weekends in Sindelfingen, overcoming project delays through unwavering dedication. “The collaboration with Mercedes-Benz colleagues was respectful, focused, equitable, and driven by a shared desire for success,” he recalled. A defining moment, he shared, was the initial drive to Sindelfingen with his team and a multitude of prototype parts. “That was truly special.”
On the return journey to Zuffenhausen, Mönig simply savored the V8 engine’s sound, window slightly ajar. Later, back in the museum workshop, he would eloquently articulate the 500 E’s enduringly superior performance. But for now, he simply relished the drive, a testament to the lasting legacy of the Mercedes-Benz 500 E story.
