Sounds like you need to recheck your connections...as for the front header touching the fan...bolt your mounts back up...I mean, I have solid LOWER mounts so when I take off my dog bones it doesn't matter because the pile of crap doesn't move anyways.

And for readjusting the wires on the starter? Nope...never had to do that on the few header installs I have been a part of...must have just been your car because the starter is definitely OUT of the way of my pacesetter's.