At this stage, possible faults include the battery voltage being supplied to the coil of the relay (or any circuit controlling this voltage), the ground being supplied to the coil of the relay (from the engine controller), and the relay itself.If the fuel pump comes on and functions properly, the fault is neither the pump nor the wiring from the relay to the pump. You can also manually close the contact on the test relay by pressing the points closed with your finger.
This will allow you to see if the relay’s coil energizes and shuts the contact when that particular circuit is energized. A great way to test a circuit is to remove the top of a relay and simply look inside. This means that the ground was so damned hot, you should be arc welding with the alternator. Consider this - it would take 500F + to melt that plastic so thoroughly.
If voltage and ground are not present while the vehicle is being cranked, check to see if the fuel-pump relay is being energized. Also, I would be equally shocked if it DID ground, that it would generate the amount of heat needed to a) melt that plastic and b) shatter that wire. If voltage and ground are present, the fuel pump has an internal failure and will need to be replaced. If the vehicle does not start, check for battery voltage and ground at the fuel pump using a Digital Volt Ohm Meter (DVOM) while someone cranks the vehicle. A 1992 engine can put out 250 horsepower. If the vehicle starts, the pump has an internal failure and will need to be replaced. The standard engine power in the C4 Corvettes ranges from 205 horsepower in a 1984 model up to 230 horsepower in one built in 1985. If not, tap on the pump while someone cranks the engine. Next, have someone turn the key to the Run position and see if the pump activates.
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