F**K, this thread is long! I had to stop on page 3 and post my opinion lol.
First off, my sympathies to the OP because I have my share of poor experiences w/ Geniuses and I know the difficulties of being w/o his/her main machine when you work with it on a daily basis.
My experience w/ computers (hardware/software) is well-rounded having to work with them for over 15 years. So, I've seen all sorts of bizarre stuff.
When I first purchased my MBP back in Feb. of 2006, I almost immediately had a fan problem where it made a noise that sounded like someone was running a playing card thru a bicycle wheel. Without opening the top case, I gently spanked it, and quickly the noise retreated. Sadly, the fix was only temporary. This light spank was "light," it wasn't like I spanked it like I would my gf in bed. Given that, the clearance between the fan and the case itself is very in fact quite a tight fit. I affirmed this by opening my case a year later. The MBPs pride themselves as a performance machine in a SMALL package. The notebook is 1" thin for crying out loud.
On with the DVI dent issue. Like another poster, I have dropped my MBP from a height of about 3 ft because my backpack strap came loose. One corner, the aluminum jitted out about 2-3mm while the other side was compressed in that same amount. I hammered it back into shape, but it wasn't perfect.
The point is, the metal casing isn't paper thin, but it isn't an inch thick either. I don't really see a way how that portion of the casing could have been bent like that w/o any form of force. Regardless of whether it was accidental damage or not, the visual evidence implies and points to user damage.
Here is the solution I'm giving you. Get the part number of the fan, order it, go to that Mac iFixiT site or whatever, take off the top casing, and replace fan. Now, call Apple and say the fan is no longer a problem.
Edit: I just realized you got ur fan replaced, grats. ZzzzZz, ignore my post.