| You really need to isolate and identify this new noise that you're referring to as "knock". Unless you've had plenty of firsthand experience of the noises, from outside the car as well as within the cabin, it's very easy to misinterpret. Could you post a video with sound? Did the noise get louder/more intense as you accelerated/ put a load on the engine? Did it get louder/quieter at a certain RPM? Does it seem like the frequency is 1/2 the speed of the RPM? There's so many possibilities at this point, you just have to inspect it further, and start narrowing it down. You're reusing some parts, it could be as simple as bad pulley bearing. It sounds like you did your homework on the rebuild, and with doing it yourself you're in the best position to identify where the problem may be stemming from. You just need more data. The RPM fluctuation sounds like a whole other diagnosis all together. They're probably not related.
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