Some things to think about (from the 2008 KK service manual):
A/C SYSTEM NOISE
When investigating an A/C system related noise, you must first know the conditions under which the noise occurs. These conditions include: weather, vehicle speed, transmission in gear or neutral, engine speed, engine temperature, and any other special conditions. Noises that develop during A/C operation can often be misleading. For example: What sounds like a failed front engine bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets or a loose compressor clutch assembly.
Drive belts are speed sensitive. At different engine speeds and depending upon drive belt tension, drive belts can develop noises that are mistaken for an A/C compressor noise. Improper drive belt tension can cause a misleading noise when the compressor clutch is engaged, which may not occur when the compressor clutch is disengaged. Check the accessory drive belt condition and tension as described in Cooling before beginning this procedure.
1. Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Turn the A/C compressor On and Off several times to clearly identify the compressor noise. Listen to the A/C compressor while the clutch is engaged and disengaged. Probe the A/C compressor with an engine stethoscope or a long screwdriver with the handle held to your ear to better localize the source of the noise.
2. Loosen all of the compressor mounting hardware and retighten. Check the compressor clutch retainer. Be certain that the clutch field coil is mounted securely to the A/C compressor, and that the clutch plate and pulley are properly aligned and have the correct air gap.
3. To duplicate high-ambient temperature conditions (high head pressure), restrict the air flow through the A/C condenser. Install a manifold gauge set or a scan tool to be certain that the discharge pressure does not exceed 2760 kPa (400 psi).
4. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusual noises. Also check the refrigerant lines and hoses for kinks or sharp bends that will restrict refrigerant flow, which can cause noises.
5. If the noise is from opening and closing of the high pressure relief valve, conduct the A/C Performance test and verify refrigerant charge level. 6. If the high pressure relief valve still does not seat properly, replace the A/C compressor.
U.S. Top Care
Chrysler Group LLC