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I'm sorry to hear about your troubles.
Sounds like the real problems here were the leak, and the sticking thermostat. The grill block wouldn't cause these problems. However, they might aggravate them.
However, I understand the caution. It's not worth worrying about it for a .5 MPG gain. I ran a block for a time too, and also removed it because it was interfering with AC performance.
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