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Do you remember if you forced the door open by hand to access the cabin filter? If the door is shut; pressing the re-circulate button on/off will lift that door for you gaining access to the cabin filter. Hmm thats all I can think of that might make that noise, if its now binding...Let us know what you find!
The lexus dealership told me they see tons of IS cars that need a new blower motor assembly because either the door gets broken or it gets caught up and binds and breaks.
If the door happened to break, get to your dealer asap...you might get it fixed under warranty...
Its around 1200 for parts/labor for the new blower motor assembly.
That's not really what happens. The owner goes to change the filter, forces the door open because he didn't read the directions, and the plastic rod with the bellcrank on it breaks. AMHIK.
Then the owner stuffs the old filter back in the blower housing and claims ignorance.
It is a huge PITA to replace the whole unit, and they don't sell the door separately.