Imac disk error after upgrade to 10.5.7

I was wondering if anyone could help out, i've having some problems ever since i upgraded to the 10.5.7
Firstly background on my mac, prior to the upgrade i was at 10.5.4, and before this i have had a few kernel panic crashes and managed to fix them, with by erase and install via my time machine with no problems.
i've decided to upgrade my mac to 10.5.7 and during the process of when i had to restart the computer after the upgrade the imac crashed, i restarted the comp manually and it got stuck on the grey screen, so i reboot on safe boot and then log back in to normal boot and it was all fine again.
But then straight after when i restart my computer the kernel panic happened again.
Now the problem is, i have erased my mac and in hope of installing leopard again and back it all up with my time machine. however everytime i tried installing i get an error saying that 'disk may be damaged', i have tried about 5 times already, i've done Apple Hardware Test as well and nothing was detected. Have run disk utility repair verify and nothing was picked up.
All of my hardware are straight from apple so i dont have any 3rd party hardwares that may cause the problems i believe.
If anyone could give me any other suggestions or help that'll be great thanks

After a little additional research I've found the following...
Upon opening a Terminal Window and entering /Applications/ I'm provided with: cannot execute binary file
Might this imply the upgrade to 10.5.7 corrupted the executable? if yes, how do I revert to a previous version? Will TimeMachine help in this?

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