If it is a 2.4 belt, then it should go on just like a stock belt would. If what you just said you know is off then thats your problem your timing is off redo it. Make sure if you haven't already to replace your tensioner. You will regret it if you didn't

 

 

It looks right to me...but photo is dark...should be black, red, and then blue at bottom.

 

 

And the plate looks right too.

 

Are your cam sensors in correct position? Exhaust sensor could be installed 180 degree off.

 

Here is my exhaust cam gear with dowl up (TDC)


Here is my intake cam gear (if you have MIVEC)

 

Actually just looked at a pic from mine. Yours is correct.

 

bad ecu?

 

 

In all the years i have timed 4g motors i have never used a screw driver for the balance shaft. Thats because they usually are gone and dont have to worry about it. But with the evo i had them for a while and just line up the marks and make sure they are all lined up and it shouldnt be an issue. You should have spotted that right away being the top timing cover off the dowell pins should have been up top not one up and one down.

 

This exactly. If the exhaust cam was installed 180deg out of phase there is a chance that your valves may have hit your pistons, hopefully i'm wrong. As long as you used the screwdriver technique when timing the balance shaft (resets every 3 turns) your car won't shake itself to death.

 

Update: Sorry to keep flip flopping and updating as I'm trying to imagine what's happening.
If your exhaust cam is 180 degree off, that means it opens during compression stroke instead of exhaust stroke. So your intake valves open during suction stroke. Then your 180 degree off cam opens exhaust valves during compression stroke and pushes all your fuel and air out into exhaust manifold. Luckily, the exhaust cams open the valves early, so they should close by the time pistons get back to top. The problem is your intake cam have extra duration so they stay open longer. OEM is 248 degrees, so intake valves stay open 68 degrees longer and then the exhaust valves open 68 degrees early, so all 4 valves are opened at same time during these overlaps, so intake and exhaust valves make contact for 68 degrees. If you have aftermarket cams, the overlap is worse. Chances are, all your valves are bent after all. Sorry to give you the bad news.

as for balance shaft, there's a bunch of videos showing how to do it without using screw driver. Give it a little push in each direction and it should want to go towards the timing mark, not away. Let us know if you need a YouTube link.
as for falling freely, mine didn't and I had 60k miles on engine.

 

Let us know if you have any updates. We want to see your engine running and making some serious power.

 

ditto