Hello, I am new to the forum. Over the past couple of days, I have been poking around at my Alero, attempting to fix some issues. Now I have hit a point where I could use some help!

Here is a little background. A couple of months ago, my girlfriend over heated the alero. I then replaced the intake manifold gaskets, spark plugs, wires.

While replacing the manifold gaskets, I damaged the FPR, and it then leaked. I installed a new one.

SINCE installing the new FPR, the car is hard to start. I have to prime the fuel pump 2 or 3 times. (Runs well, No codes.)

ALSO, my fuel mileage has been cut in HALF, literally. I got 56 miles per half a tank.

Yesterday, I hooked up a fuel pressure gauge. To get any pressure to register, I have the cycle the key 15-20 times and it shows 20psi, and slowly bleeds off. If I run the vehicle with the gauge attached, it shows a steady 40psi. If i remove the vacuum line on FPR, it shoots up to 55-60psi. As soon as I turn the engine off, it takes about 45sec for all pressure to bleed off.

I can not find a fuel leak ANYWHERE, and the oil doesn't smell like fuel, so I doubt it would be an injector. Actually, there is no fuel smell anywhere, no black smoke, etc.

Does it sound like the FPR could be a junk one? Any other ideas?

Any help would be greatly appreciated!!

Could be a faulty one.

A new FPR should be cheep enough to try a new one. I would make sure it'* a AC Delco or Delphi part though. Rockauto has a closeout price on a Delphi regulator right now.
RockAuto Parts Catalog

Did you ever figure out what was wrong?