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The flex fan could be part of the problem. Some people are going to disagree with me on this, but for a STREET car it will be hard to beat the ford factory fan. If you are racing then electric would be the way to go, but for a street car stay with the stock fan set-up. It will also save you...

I had the exact same problem with my car and I MEAN exact minus the knocking. After replacing many parts including head gaskets, intake gasket and the intake itself, installing a electric fan in addition to the factory one (mounted on the front of the radiator), thermostats, no thermostat. Still...

Actually, the cats will be cooler without the smog pump hooked up. The smog pumps purpose is to introduce oxygen into the cats to help the burning process.