1989 245 AT non-turbo
Bringing it back to life after finding it where it sat for at least a decade.
Just got done replacing the freeze plug on the side of the head. It was way gone, water just poured out of it.
Did the whole remove the exhaust manifold, etc.
Also did the water pump, timing belt, valve cover gasket and lots of cleaning from a VC gasket that must have leaked for years. It was a Black Block and now looks like a Red Block again.
Flushed the cooling system that ran orange it was so neglected.

Started to refill with water and discovered that the freeze plug that is on the underside of the front of the head is just as bad as the one on the side. The one where the head hangs out over the block. Makes sense based of the poorly maintained cooling system.
At first look it seems like the head will need to come off to replace the plug.
But after taking a closer look and thinking about grinding off a very small portion of the corner of the block that very slightly cover the plug hole I'm thinking about taking a shot at replacing it with the head on.
Anyone ever done that before?
Are there any other hidden freeze plugs I should look for? The 2 at the front of the head look great like they have already been replaced.

Also, without the special tool any trick to get the bolt loose on the intermediate shaft pulley? Someone must have really cranked this one down. The cam pulley (which has the same torque spec) came off no problem but even with the belt still on the pulley will just jump cogs on the belt. been trying the screw driver through the pulley holes and a breaker bar still no luck.
TIA

Pic of plug is using a mirror.

 

I would just remove the head, get it checked out for warpage, fix the freeze plugs, put on a new head gasket and make it right.