05 Hybrid Battery cell replaced

Welcome to Prius chat... I suspect your problem is that there's 14 voltage sensors (one for each block / 2 modules) and those blocks need to have near the same voltage/be balanced.

Usually replacement modules will have been reconditioned before you buy them so they'll have better performance / voltage numbers than other modules in the pack. And because you replaced both of the modules in that block (a common mistake) you're doubling down on that block giving different voltage numbers.

So if you're lucky and you pull that module you didn't need to replace, things might work out. But in general, I never replace a module on a pack until the pack has been reconditioned (each module discharged and recharge 3 times at increasingly deep levels). And then when that time consuming work is done I put the pack in the car and use hybridautomotive.com equipment to charge and balance the pack.

Old Prius packs will have as low as 50% capacity remaining and reconditioning/deep cycling can restore capacity up to 96%. Here's more info on the basic science of it: BU-807: How to Restore Nickel-based Batteries – Battery University

 

No not 22, it is indicating it is not happy with one or both of the modules in block 12. Blocks and modules are counted as in the picture below.

You could try balance charge/discharging the complete HV (hybrid vehicle) battery for 3 cycles and then see whether it is happier after that.

 

Your graphic doesn't translate module/block numbers to error codes... This confuses people often and if I was more clear on it I'd correct the graphic. Can you or anyone else for once and for all clarify block code error confusion? Surely there must be link on here that correlates which block code error corresponds to which module/block? I keep thinking I got it figured out but then I realize I'm not certain? You also seem to be challenged by the same problem.