Just spotted a few typo's with my original post.
No every thing is as original state. All guards seem ok. Double checked even during the week.
I was doubting the explanation also, intercooler fair enough, possible damage could be done through a front grille entry, but this latest issue not so inclined to believe the explanation.
Forgot to mention also, last summer (2012) AC not working, our usual dealership re-gassed stating that it's not too uncommon that a leakage may occur with moving parts, pipework etc, think they used a dye in the gas also to track the fault.