Over the weekend I installed at pacesetter header on a 2200, and I had it welded to the cat. But....accelerating I hear a hissing whistling sound, is this normal? I also have a 56mm throttle body btw. Midas rechecked my exhaust and found no leaks. What could it be?
I actually had the same problem with my 2.4L. I thought it was the manifold gasket but that actually wasn't the problem. The problem was with the downpipe not sealing correctly to the header. At idle it sounded fine but when I accelerated it sounded whistly. This was because when the engine moved when accelerating the piping would come a little loose. This happened even with engine mounts. I had a shop fabricate and install a new downpipe that fit better. If you are using the downpipe that came with the header you might want to get a new one made.

"Kneel before ZOD!!!"
D-LuxZ24 - Yea that'll be an option. I'll take a look at the connection when I get home today.
I was going to say try some motor mounts, but i see you already have those. Have someone rev the engine a little bit in neutral and get on the ground and listen. Just to make sure its comming from the down pipe and not midas's cheap welds.
I was actually there when they re-checked it......but when I was under the car I could hear it from where the header connects to the downpipe, but I connected everything as It should be. Is there something im missing?
When you connected the header to the downpipe, did you use the springs it came with (along with the bolt, washers and nut?) If you did use them, they should be COMPLETELY compressed. There should be NO space between any of the coils.
When I installed my temp. header this summer, I tightened those bolts down well, and the car "hissed." So I went back and re-tightened them like I said above, and no problems again.
I just went out and visually checked the bolts, The springs are fully compressed. When I tightened the bolts down I did a lil on one side and switched to the other, until the spring were fully compressed. That is how u guys did it right?
you dont want the fully compressed , but you want them close
are you sure your not just hearing a normal noise ?? headers do make a different noise in the exhaust , that a cast iron manifold doesnt
That is true I noticed that the headers sort of sound like my intake (I have an AEM WAI with a K&N filter). If you have your radio off you can hear the exhaust going through the pipes. Not too loud, but noticeable. Almost sounds like blowing air through a straw. Maybe this is the source of your noise.

"Kneel before ZOD!!!"
maybe....it does kinda sound like that, like a wooshing whistling sound....it'll just double check the bolts.
It's an older thread, but it works, the shop I'm taking my car to wants to weld my header to my downpipe (Where those two bolts are). Is that right?
http://www.cardomain.com/ride/2265283
that'll be on option, I re-tightened my bolts and it was fine.