(1) Yes, by the definition of maximal.
(2) Yes. Technical detains in Is Zorn's lemma required to prove the existence of a maximal atlas on a manifold? and Why maximal atlas.
(3) I understand that the "they" in "And if they are not compatible..." are two _charts_. Yes, each chart is in an atlas _and the intersection of both atlas is empty_.
(4) They give _different_ structures. But can be _diffeomorphic_. Easy example: $\Bbb R$ and the two atlases $\\{x\longmapsto x\\}$ and $\\{x\longmapsto x^3\\}$.