Aftermarket Headers
A Must for Headers
Aftermarket headers are use to improve an engine's performance. The goal of these headers is to make it easier for the engine to push exhaust gases out of the cylinders.
First thing we must stress with aftermarket headers, have them professionally installed by a credible garage. Some budget headers may need modification for proper clearances. A do it yourself (DIY) install can be difficult and frustrating.
Next, we also stress that you never drive public streets without a catalytic converter. Whether you use a basic converter or a hi-flow (performance) converter, a proper street exhaust set-up consists of a catalytic converter. Aftermarket headers DO NOT come with a catalytic converter, one has to be custom fitted to the system.
Need to Know (before installing)
The first thing to know about your Hyundai and aftermarket headers is that they eliminate the OEM catalytic converters. This will have an effect on proper placement of the existing exhaust sensors. Oxygen Sensors (O2)
Oxygen sensors are part of the emissions control system and feeds data to the engine control  module (ECM). The goal of the sensors is to help the engine run as efficiently as possible by monitoring the air/fuel ratio to produce as few emissions as possible. The oxygen sensor is positioned in the exhaust pipe and can detect rich and lean mixtures. The engine's computer looks at the voltage to determine if the mixture is rich or lean, and adjusts the amount of fuel entering the engine accordingly. When a sudden change in the system is made and the ECM is unable to make the proper adjustment the check engine light (CEL) will come on.
Keep in mind that the sensors and the ECM are not smart, the units are just doing what they are programmed to do. Even a positive change in the system, yet rare, can activate the CEL. For example, if the dealer replaces the OEM exhaust manifold and close mount catalytic converter with a new unit, this can activate the CEL. Although the change is positive, it is still sudden and ECM will need time to adjust. Under normal circumstances the ECM will adjust itself after a short drive around the block and the CEL will be de-activated on the next start up. A simple reset of the ECM can also de-activate the CEL. In some cases (aftermarket headers) it can take up to a week of normal driving for the ECM to make proper adjustments.
Sensor Bungs
A sensor bung is a threaded lip located on the exhaust manifold that the sensors  screw into. Most aftermarket headers do not come with sensor bungs. If the header does come with bungs, normally only the first set of bungs can be used. When a catalytic converter is added to the system, the last bung (flexpipe bung) is not used and a new bung needs to be added after the catalytic converter. Sensor bungs can be easily added by any shop and runs around $20.00 - $40.00. When a new bung is added after the catalytic converter the wiring for that sensor will need to be extended to reach the bung.
After the Install
After headers are installed you will notice some things that may become of some concern.
Sounds and Noises
The first thing your going to notice is the sound. Headers have tendency to create a louder sound from the exhaust system, especially when you upgrade from an OEM system. The sound is sometimes described as a buzzing. Normally a buzzing sound means that you're running with-out a catalytic converter or running an aftermarket catback system with-out a midpipe resignator or you do not have either. Higher priced headers are designed with equal length piping and precise bends so they have a tendency to create less sound and buzzing. Keep in mind that if the buzzing does not dissipate after several weeks you may want to consider installing a catalytic converter or a midpipe resignator or even both. If you like the sound, then leave it alone. Also keep in mind that aftermarket mufflers designed to produce a loud sound will magnify buzzing sounds.
Smells
The next thing you will notice is the smell. The scent emitted is sometimes described as a fishy smell. The smell is from the protective coating and gasket chemicals burning off from the high exhaust temperatures. This is normal and will go away after a day or so.
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