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Sounds like you have the basics covered.
Random thought, if they're not finding an issue directly in the cooling system is it possible the issue has to do with the active kidney grill not being able to always open properly?
On cold starts the grill remains closed to help the engine warm up faster after which, it opens up. If it's not opening up properly all the time, it will take longer and be tougher for the AC to cool off since a closed grill has got to have a general negative effect on heat exchange.
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