OK, here is some more information to add to the general body of knowledge about this upgrade.
First, as I said earlier, this 5.5 liter tank
does fit into the standard North American TDI without any problems. I saw a 2002 Golf TDI with the same smaller (North American spec) engine in the showroom of my dealer in Konstanz, Germany last week, and it had the 5.5 liter tank in it.
Below are photos of the tank, front and back sides, and also of the second, larger pump that is used to supply pressurized fluid to the headlight washer assemblies. The second pump fits into the front of the tank assembly. The existing pump that is supplied with the North American cars (windshield pump) fits into the rear of the tank, using the existing pump, wiring, and sealing ring.
There are three holes on the tank, one each for each of the two pumps (front and back) and one on the front of the tank for the fluid low level sensor.
I won't have time to install this tank into my 2002 Golf TDI for about 4 weeks, due to a busy work schedule, but when I do install it, I'll take the usual photos and post them here.
The prices indicated on the photos are in Euros, they are the
net list price that I paid at the dealer in Konstanz in February 2002. Note that the sales taxes (about 20%) are not included, and note also that if the parts are purchased in a different country (e.g. the UK), the prices may be higher.
For those of you who do not plan to retrofit the headlight washers, my guess is that you could just purchase the sealing ring for the front pump (costs about a dollar) then install a stainless steel bolt and nut in it, to plug the hole. Be aware that the sealing ring for the hole on the front of the tank is a different size and different part number than the sealing ring for the hole on the back. I don't think that the front side sealing ring is available from VW parts departments in North America, but I have not checked this.
Front view of 5.5 Liter Tank and Front Side pump assembly (headlight washer pump)
Rear View of 5.5 Litre Tank
Second (front side) pump used to supply headlight washer system