and found this during reassembly. looks like a flap for something? any guesses?

 

I have a 2003 XK9 that I pulled the intake also to do the valley hoses and didn't see that laying around under my intake.

 

Yep, got one on my '02 4.0L

 

if you are doing the valley hoses I assume you will have the same hose, the valley hose on the passenger side going back the octopus hose, there is a metal tube like connector there between the hoses. There is a SMALL hose there that goes off that tube to the TB area, I forget. Check that hose, mine was all bloated to hell and back there at the connection between the valley hose and the octopus hose on the passenger side. bloated equals REPLACE. That will be the easiest time to replace. I would do it even if it looks good.

 

where?

 

If you are keeping your car for awhile I would strongly encourage you doing all the hoses on the cooling system. Yea I am spending your money in saying that but it is a good selling point for those looking for a car lie this to know this stuff has been fixed. Won't get you more money but a buyer knows it is fixed and puts your car above most all others that the owners have no idea what has been done to their car.
I assume you have pulled the whole intake off? Did you take the plenum off the metal part of the intake?

 

Almost dead center on top of the engine block, at an angle to where it looks like a diamond. I believe mine is held in place by an adhesive? I'm out of town for the moment otherwise I'd take a pic for you. I'm in the process of doing all,my cooling hoses as well. Get all that you can through rockauto.com they are about 1/2 the price of anyone else online. No, they don't have the octopus hose, SNG Barrat has that one for the lowest price I could find. Rockauto does have that stupid hose that goes between the thermostat and the water distribution contraption that normally goes for 20$ for about 3$. Worth checking into.

 

Thanks. wonder what it was for, car works fine without it.

like to see your pic of it. I might put it back in.

 

Will do when I hit town this weekend

 

did all heater hoses as it is due, no real swelling noted.
I removed the intake, TB elbow and TB as a unit.

hint for others connect the vacuum tube to TB elbow before reinstalling. major PITA, I had to remove the TB after it was all done to attach new tubing.