Re: C3 big block head removal
For what it's worth, I recently removed my evaporator core box from my '72 454 to fix a similar hole next to the manifold bolt. It really wasn't that bad. In a big block, you'll need to separate the evaporator core portion from the fan housing and remove the two pieces separately - there is NO room to rotate them and lift out as one assembly. There are only 6 screws holding the two halves together. Unfortunately, you will also need to drain and disconnect the radiator overflow bottle, wiper door vacuum motor as well as the evaporator core, POA valve, etc. That, of course, is after you remove the map pocket, two support braces, and a number of ventilation components on the passenger-side interior. This was all worth it for me, as I had a number of bad vacuum components and a leaking heater core as well.
Reassembly of the fan and evaporator core under the hood wasn't all that terrible - it was a lot harder to reinstall my speedo/tach cluster! I used the HVAC seal kit from Dr. Rebuild - fairly good, not perfect, but much better than what was left after almost 40 years of deterioration. The AIM isn't very good at identifying which screws go where (and there are a number of different lengths), so make yourself some good drawings and label fasteners and put them into baggies as you take them out.
Good luck!
For what it's worth, I recently removed my evaporator core box from my '72 454 to fix a similar hole next to the manifold bolt. It really wasn't that bad. In a big block, you'll need to separate the evaporator core portion from the fan housing and remove the two pieces separately - there is NO room to rotate them and lift out as one assembly. There are only 6 screws holding the two halves together. Unfortunately, you will also need to drain and disconnect the radiator overflow bottle, wiper door vacuum motor as well as the evaporator core, POA valve, etc. That, of course, is after you remove the map pocket, two support braces, and a number of ventilation components on the passenger-side interior. This was all worth it for me, as I had a number of bad vacuum components and a leaking heater core as well.
Reassembly of the fan and evaporator core under the hood wasn't all that terrible - it was a lot harder to reinstall my speedo/tach cluster! I used the HVAC seal kit from Dr. Rebuild - fairly good, not perfect, but much better than what was left after almost 40 years of deterioration. The AIM isn't very good at identifying which screws go where (and there are a number of different lengths), so make yourself some good drawings and label fasteners and put them into baggies as you take them out.
Good luck!
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