This , from Suzuki forum should help you ,
Hi all you dashboard rattles,
Found the cause in my case of the SUZUKI death rattle, I would like to say I found it but it was on Suzuki -Forums.com.
The writer name Tim McCabe look under Dashboard rattle there's a great picture on the mod.
Took me 45min to do the mod then SILENCE
It turn's out to be the (3) flaps in the air box which controls the direction of the air flow, in the tube's under the dash, which could account for the rattle coming from various sides of the car, as the flap move's and is not under air flow presure, the end which just sit's in the plastic boss is free to rattle (the other end is held firm by the control solenoid) .
1. Working on the driver side, remove the panel under the steering wheel (3 screw's) and the panel below that (2 screw's).
2.Now looking up to your left at the top, you will see the 3 small boss's protruding out of the white plastic air box, this I believe is where the
rattle is coming from.
3.Using a hand drill, or an small elec drill, make a small hole in the side (3mm drill) of the 3 boss's DO NOT DRILL TO DEEP just enough to get some grease onto the shaft. It worked for me.
4.If you are not to sure this is for you, try this when the rattle is driving you up the wall, turn your blower to max boost, and then change the air flow to differant part's of the car,the air presure hold's the shaft and flap tight into the boss in the air box if it stop the rattle, the next move is YOURS. .
I hope it works for you, and it overcomes this very annoying problem
Cheers Bob.
Ps will keep you updated
Posted Apr 3, 2011 (13 years ago)