Got my '04 HP back with the new engine. Within a few days started getting a howling/revving sound from A/C above 3500 rpm. With only a couple of VERY packed and stressful days before a houselhold move from TX to FL, I just didn't use A/C above 3K (miserable trip...).
Few days after arrival I start getting the squeaking/whistling sound. I figured belts must have been improperly tensioned. Plan on getting it to a dealer as soon as I can. I took a look tonight to confirm, and what I discovered is that the idle pulley sits back a little too far, which has caused the belt to grind against the shoulder of the A/C pulley. You can see that about an 8th of an inch is already sheared, and there is about 1/2 space on the front of the A/C pulley.
Flipping through the service manual I could not find any details about the idle pulley and how that is possible. Don't know if there is a spacer or something that the tech may have "lost", or what... Any ideas? Hopefully will take it in tomorrow.

 

Just got word today from my service department. It wasn't the idler pulley out of whack - it was the A/C compressor itself. Seems that 2 of the 3 bolts are missing (!) and the remaining one was very loose. They are trying to source new bolts and determine if the threads are stripped. Unreal.

 

dang thats crazy