Remove the intake manifold, exhaust manifold, and then remove the head. Scrap off the old gasket and install a new one. Reinstall the head and Torque the head bolts in the proper sequence.
BTW ~ the bolts usually sieze to the manifold flange rather than the threads siezing in the head. Provided you can get the manifold off, removing the broken bolts should be easy enough with a good quality (ie not Chinese) self grip wrench.
This is a common problem with exhaust manifold bolts, guys at machine shops most likely deal with it all the time. Maybe you can get your heads off with the manifolds on? If the bolt heads were torched off the remaining stud could be grabed with vise grips eliminating the need for drilling and extractors.
How to Remove Exhaust Manifold Bolts. Spin 1 lock nut onto the exposed threads, but do so with the cast lock of the nut facing out. You are putting the lock nut on backwards. Put the other lock nut on in the normal fashion. Make sure they are tight together. Attach a socket wrench to the top lock nut.
If the bolt is deemed salvageable, Remove as much rust off the threads as possible. A stiff wire brush and a little elbow grease goes a long way toward happy results. Step 3: Remove as Much Rust.
If all these methods fail to remove the broken bolt (yes, I had this happen plenty of times over the years!) then the only choice is to drill it out completely. This means drilling away the mating threads where the bolt was fastened. In this case you will have to tap new, larger threads into the hole and find a larger bolt to use in that location.
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Ultimately I would have it towed leaving behind a sad little pile of rust and nuts and bolts. With a bonus check in hand for. but the temperature and a sensor in the exhaust that senses how.
A few of my tips to help remove stubborn half disintegrated exhaust nuts, when you don’t have an acetylene torch availible! Metri-inch sockets are a great in.
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Inside the K04 turbo, SoCalPorting worked its magic with a full port and polish on the turbocharger and exhaust manifold to clean up the flow. Braille replaces the conventional lead-acid anchor,