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I have 73000 miles, initial problem NO Heat, then Check lite. Brought Fusion to Dealer, Radiator fluid running out of exhaust. Major Engine problem. Fusion left at dealer Nov 22, 2016, may get it back second week of Jan 2017. Purchased ext. warranty, parts and most labor covered(initial costs over $5000).

Question: Is there a issue with Aluminum Header and Cast Iron Block?
 

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Welcome to the FFO!

Assuming your question regards dissimilar metal.

There isn't an issue with dissimilar metals in the engine as long as the engine was assembled correctly* and coolant is serviced as shown in the owners/maintenance manual with the correct coolant. Auto manufacturers have been using major aluminum parts with cast iron parts for a very long time. The head gasket may be different as well for this arrangement. However the only controllable piece is the coolant. The coolant has been developed to operate in that type of mixed metal engine and not all coolants are the same. It is extremely important to use the correct coolant. And then to change it out as required.

*Typically if there is an engine assembly issue it will show up rather soon after the first start up.

If that was not your question please clarify. And since there are several engine choices clarifying the engine size would help as well.

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