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2006 V50 owner here.
What do you conclude made the difference in mileage? Your manual 4 cyl is probably better than my auto 5 cyl for mileage. I get 32MPG on highway trips and ~26 around town.
I don't think there's much potential for grill block - Volvo has done a lot of that thinking already.
The only major areo mods I see are a lawn-edging chin spoiler and rear wheel spats.
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