Something on the level of the STAR tool or DRBIII is required to reset the ORC module.

1) No, removing the wheel is not necessary. Others have made this mistake but Bob McCubbin in Olathe, Kansas (he's on the forum) has found a way to avoid removing the wheel. (Not saying he invented a way, just that he knows a way.)
But it's too late for you.

2) If the battery was disconnected while doing the work, I would believe the real issue is that the connector is not plugged in all of the way or that the clockspring is at fault.

3) IF you freaked out the ORC module because you left the battery connected, know that there are at least two versions, based on year of the car - 2007/8s are a different module.
3A) You can use a used module, but apparently, you must have the 'new' module reset BEFORE you put it in the car (not sure on this but this is what I gather from other threads).

Are you SURE the connector is seated properly? Did you or did you not disconnect the battery while tearing into the car?