tdci intercooler veins
 

On the bottom vein on my tdci intercooler the bottom vein has expanded mishaping the intercooler. It has ballooned basically. Does anyone know how that has happened? I can show you a pic if you need.

nobody?

sounds really strange but could it have been a blockage that has caused this?
you can get a 2nd one off ebay cheap so i'd remove it to see if there are any visible issues causing it.

Is your focus a mk2 ? This happened to mine too after owning it a week , it eventually blew out spraying oil over the front of the car ! Think it was a fault in the car due to a bracket breaking and the intercooler not being supported. Hope that helps mate.