Someone in another thread asked that I post my solution to the IAT problem with my '18 TXi, so I decided to revive this old thread and post it here. Apologies in advance for the REALLY long post. I wanted everyone who has this problem to have all the info.
I've been using this solution since about May, including rapid fire course skiing, also in 100deg+ weather, so I'm very confident I've solved this for the long haul. Be aware though, my solution is a band-aid, but a very workable and easy to apply one. Also, I'm not a mechanic or an engine expert, just someone trying to troubleshoot this annoying problem.
First, a summary of the IAT problem (hopefully saving others from having to piece together the same info from the above thread). What people have seen is that the 17-19 TXi, after being run for a while (like skiing a couple sets worth) starts to have noticeably slower starts. Typically the solution has been to open the engine cover for a few moments, letting the hot air out (unacceptable from my POV). Upon further investigation, it turns out the engine's Intake Air Temperature (IAT) going above 140degF triggers the engine's electronics to hold back the timing and engine output (the cause of the low engine performance and slow starts). One note - IAT is NOT the temp you see on your dash's main screen. To see the IAT, you need to go to "Settings" and "Engine Diagnostics" and look for the IAT line. Also note, the IAT is only accurate if the engine is running.
Now for my many conclusions based on my testing earlier this year. These are based on a lot of conversations with Dennis Kelly at Malibu (who has been a fantastic help), and a ton of in-boat testing, including temperature sensors added in different locations under the engine hood.
Conclusion #1 - Is there a problem with the TXi's air path? No, I don't believe so! When the boat is moving (causing airflow through the vents in front of the windshield), the IAT always seems to go DOWN, proving that air is moving through the vents, the ducts in the boat's hull, and through the engine compartment. Could it be better? Maybe. Hard for me to judge
Conclusion #2 - When does the IAT climb? After the boat stops moving after a high RPM run (like a skiing pass). Obviously not ideal for a ski boat. As soon as the boat begins moving again though, the IAT goes down, but when you stop at the other end of the course, the IAT climbs higher again, and usually higher than the end of the previous pass, eventually climbing above the 140deg.
Conclusion #3 - How accurate is the IAT? Is it really that hot at the flame arrester (the silver mesh dome at the top/front of the engine - where the IAT sensor is located)? - When the boat's at rest - YES! The IAT was always within 5degF of my added temperature sensors when the boat was stationary.
Conclusion #4 - How quickly does the ACTUAL temp in the top of the engine compartment go down? Almost instantly once above about 10mph. HOWEVER, the IAT reading on the dash touchscreen never seemed to react that quickly - there was always a lag (which might be the sensor, or the touchscreen - who knows). This lag seems to be a contributor to the IAT problem as the engine thinks the temp is higher than it really is for the first few moments of a pass.
Conclusion #5 - Is the close proximity of the alternator to the IAT sensor the cause of this problem? Probably not - but it isn't helping things. Dennis sent me one of PCM's prototype heat shields - a piece of metal that you bolt between the alternator and the flame arrestor. But guess what - it's metal! And it did what metal does, conduct heat - so within a few minutes, the shield was nearly as hot as the alternator. I then wrapped it in insulation, dropping the shield's surface temp much lower - but it still didn't solve the problem. The IAT did seem to climb more slowly, but eventually it crossed that 140degF threshold.
Final Conclusion - Heat buildup when the boat isn't moving, along with additional heat from the alternator, along with a slowly reacting temp sensor - combine to create the +140IAT reading, causing the low-engine performance.
Now to the solution I'm using. This is largely based on @jstaab3 's addition of a secondary blower into the engine compartment. But Jason sent me a video of his, and the noise was just too loud for my liking. So I set out to find a high CFM, low-noise blower that could work. I then found a place to mount that blower lower in the engine compartment (cooler air), and then duct that air efficiently (without losing air flow) directly up to the flame arrestor and the IAT sensor. In testing many different ways to do this, the ONLY way it worked all the time was to blow air RIGHT on to the flame arrestor.
Here are a few photos of the install:
These are the parts I used. Total cost $110:
Bilge Blower 112cfm: https://tinyurl.com/yxo3f5bv
Shop Vac Hose: https://tinyurl.com/y3otgkfe
Shop Vac 90deg Brush: https://tinyurl.com/y3f2tdgb
I mounted this very quiet blower in the rear-portside corner of the engine compartment. At least on my boat, it actually sits there on its own, but I did add a piece of Velcro to the back of the blower motor, and attach it to the end of the fiberglass floor (see below)
For the hose, the more rigid shop-vac hose moves air very efficiently. Luckily, this particular hose has an end that perfectly press-fits into the above blower (not designed that way - just lucky). I also cut the hose to the perfect length, and moved the hose connector (easy to do).
At the sensor end, I took the 90deg shop-vac brush, removed the brush part, which gives you an efficient 90deg bend (MUCH more air flow then bending the hose).
I then zip tied the hose down along the path. One note - you MUST remove the red engine cover (just pull up on it). The hose will not fit under it, or over it. One more thing, I left the heat shield in place (you can see it in the photos above), which made mounting of the 90deg elbow easy. But I think it's doable without it too.
To finish this off, I wired the blower into the boat's electrical system by disconnecting the LED within the engine compartment (this is under the fiberglass floor plate that wraps the pylon - remove the three screws, and carefully slide the floor piece up. Be very careful not to strip out the fiberglass when you reinsert the screws!). You can see a photo above in my post from Sept 2018. I simply disconnected the LED, inserted the power leads from the blower into the connector, and carefully wrapped with electrical tape, then zip tied it so it would never sit in water at the bottom of the engine compartment. I will likely buy the same connector over the off-season and replace.
With the blower wired into the system - I can turn it on/off by using the "Storage" lighting control switch on the touch panel.
The end result: I now have easy control over this nearly imperceptible blower, which keeps the IAT at approximately 125degF, and the best part - the TXi is now a BEAST! All the complaints from my ski buddies are gone.
One thing you might be wondering - will this band-air hurt the engine. Again, I'm not an expert, and I suppose I'm taking some risk applying this fix, but I came to the conclusion the risk was minimal. I leave this blower running the whole time I'm skiing anyone, which seems to keep the air temperature in the top of the engine compartment quite consistent, not just at the IAT sensor.
I hope the above helps at least a few of you. If you have any questions, just post and I'll try to reply as soon as possible (I'm on a skiing staycation this week!)