Okay, so maybe your problem isn't with header_php.php files nor html_header.php.
It's possible that you've customized something that's attempting to do a zen_redirect or is making a header() call from within a main_template_vars file or a template file, which will cause this sort of problem because you can't do a redirect like that once output has been sent to the page, and since html_header.php is where the output first starts (just as the error message says), it's just showing you a symptom, not a root cause.
So, since the header_php file load first, then html_header, and then the main_template_var files and then all the templating system, you need to focus in the latter sections.
Ref:
http://www.zen-cart.com/index.php?ma...roducts_id=378