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I don't see why you wouldn't see 40 mpg; my Saturn Ion is a larger car with a 2.2L engine, and I've been kissing 40 mpg lately.
About the grill block, I wonder how the decrease in drag from the grill block compares to the extra alternator draw from the fan. Is it possible that running the fan actually yields better mpg than leaving the grill open? How about a variable speed fan controller based on temperature? (i.e. start a slow spin at 190 degrees, slowly increasing to full blast at 205.)
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