The 1.8 duratec is not immune from a severely worn cam chain tensioner.
I know you say the chain is ok but is that solely from looking from the valve train/rocker cover end?
Have you checked all your timing marks line up?
If not I would do so and don't crank over with the starter anymore until it is confirmed that they do line up.
I've got in my head that the 1.8 is an interference fit engine & it's not beyond the realms for a slack chain to allow the chain to slip a few teeth which would coincide with non starting and knocking as the valve train slaps the top of the pistons.
In contradiction to my thought pattern of don't crank it until timing marks are confirmed, if your struggling to locate timing marks a quick compression check will show up valves running out of time.
Let us know how you get on.
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