First thanks to everyone for their 2 cents! This Forum is a great tool because of folks like you.

After reading your feedback I was 99% certain my problem was the 2nd stage of the Aux cooling fans. Having never heard of the second stage I was convinced that was the problem.

I parked the car with the AC running...
- Stage one fans ran fine
Coolant Temp started to rise and then to my surprise...
- Stage two fans kicked in running hard

Just before I slamed the hood in disgust something about the passanger side Aux fan caught my eye.... The thing was running CCW !!! (Driver's side was correct CW) Appearantly when the passenger side Aux fan was replaced some bonehead plugged in the connector reverse. With the fan pulling instead of pushing air the system had no chance of catching up.

5 minutes to rewire the fan in the correct rotation and my problem is gone.

Now here's the hard part:
I'm the bonehead that last plugged in the fan connector.

Wow that was hard to say, but I'm just glad I'll be enjoying some nice AC on the way home today.

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2002 E55 Stock
Sold my project car: 1993 300E (3.2L) Blower running 0.8 Bar, Re-badged E32 Kompressor, Apexi Piggyback ECU, 310cc injectors, 255LPH Walbro Fuel Pump, Water/methanol injection, Quad SS Exhaust Tips, 3" SS exhaust with high-flow Cat, 17" Monoblocks 225/45/17, Brembo BIG Brake upgrade, Euro-headlamps, clear corners, Euro-tail lamps, keyless entry, CD AMPs Subs etc...

Photos: http://share.shutterfly.com/share/received/welcome.sfly?fid=c20c2dad4373aa89&sid=0CbuXLVo5cMXFg