I feel like im in your shoes. I've tried all the things possible to rule out the damn control unit under the stereo. but no matter what I do 2 things must happen for the ac to blow cold in my car.

1. Car must be at operating temp
2. I must rev to min 4000 rpm.

aside from all the normal fan checks and nonsense if these things don't happen for me nothing is ever cold.

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1997 E39 540i (Sold)
2005 E53 3.0 125K miles