First of all I'd like to thank the OP for posting this write-up. It's among the most helpful I've seen regarding head removal on the M42.
I recently undertook the task myself, and now that I'm reassembling the engine I've run into an issue of concern.
I'm to the point where the engine spins fine without the chain tensioner installed, but one I install it I can only turn the motor over a couple of times before the engine binds up. I'm not sure why. Is this normal as oil flows into the tension unit?
If I loosen the 19mm hex cover that holds the tension device in place even a few threads the engine spins freely as it should, four whistles and back to TDC.
It seems like the chain is binding up under the modest oil flow from hand cranking the engine, and what's weird is that I can turn the motor over again after it sits for a few minutes. I guess this might be normal, but I don't want to fire the engine until I know it will spin free with all of the timing gear installed.
Any advice from others who might have had the mixed fortune of completing this task before?
Cheers,
--Ben