Tesla Battery Replacement in Canada: What One DIY Disaster Can Teach EV Owners in Vancouver

Electric vehicles are engineering marvels—but the technology that powers them is incredibly sensitive. Chief among those components? The battery pack. In our latest video at Greentec Auto, Art, our CTO and EV battery expert, opens up a Tesla battery sent in for repair—only to discover it was flooded with nearly 10 centimetres of standing water. What went wrong? And what should every Canadian Tesla owner know before trying to replace a battery themselves?

Let’s break it down.

The Hidden Danger in a DIY Tesla Battery Job

Roughly ten years ago, Art posted a video dissecting a flooded RAV4 EV battery. Fast-forward to today, and he’s encountered another case—this time, a Tesla battery rebuilt by a DIYer or local shop and shipped in as a “core.” From the moment it arrived at our facility just outside Vancouver, it was clear the battery had not been serviced properly.

What happened? It all started with poor resealing after the battery lid was removed.

What Went Wrong With This Tesla Battery Replacement?

Here are the key issues our team uncovered:

1. Failed Seal from Bad Glue Contact
   The resealing process left large gaps where glue failed to bond with the lid. In some spots, there was no glue at all. Leftover adhesive from a previous job had never been cleaned off, stopping the new glue from forming a watertight seal.
2. Incorrect Glue Type
   Even where glue was used, the wrong adhesive had been applied—likely something not engineered for EV battery applications. Without proper chemical bonding, the pack was wide open to moisture.
3. Bolts Installed in the Wrong Sequence
   The battery lid had been bolted down in a pattern that caused uneven pressure. That mistake warped the lid slightly, allowing water to slip through along the edges.
4. Warped Lid from Improper Removal
   Instead of using the correct method to lift the lid, the handler bent it using what’s often called the “butterfly method.” This shortcut caused a permanent valley in the centre—another entry point for moisture.
5. Patchwork Repairs Instead of Full Servicing
   Rather than checking each module, the rebuild focused on fixing only visible issues. That left other areas completely vulnerable.

The Aftermath: A Soaked Tesla Battery Pack

By the time we got the pack open, nearly four inches of water had pooled inside. Even after drying it for over a week, it remained one of the most water-damaged Tesla batteries we’ve ever seen at our Canadian shop. Moisture like that doesn’t just lower performance—it corrodes vital electronics and creates fire risks or short circuits.

How Greentec Auto in Canada Does Tesla Battery Replacement Right

At Greentec Auto Canada, we take a very different approach—especially for our customers in Vancouver and across B.C. Every battery that enters our shop is handled with precision, care, and a system developed through years of experience.

Here’s how we do it:

✅ Engineered Lid Removal
We never force or bend the battery casing. The lid is removed using tested methods that keep the original seal shape intact.

✅ Full Glue Removal
We clean off every trace of old adhesive and use only Tesla-approved glue, ensuring perfect bonding every time.

✅ Complete Internal Service
Our techs inspect and refresh every module in the battery—not just the visibly damaged ones.

✅ Bolt Sequence Done Right
We use an exact bolt pattern to avoid pressure warping, ensuring a tight, even seal around the perimeter.

✅ Pressure Testing Every Battery
Before it leaves our shop, every battery is pressure-tested to ensure it’s completely sealed—because if air can get in or out, so can water.

Why Vancouver EV Owners Should Care

Whether you’re in Vancouver, Richmond, Surrey, or Burnaby, if your Tesla battery needs work, make sure it’s done by specialists. A $10,000 battery pack is not something to gamble with—and cutting corners could leave you with a soaked, shorted-out battery that can’t be repaired.

DIY repairs might seem cost-effective at first, but they can cost you far more in the long run. If you’re considering a replacement, talk to our Canadian team first.