fix: fail fast on silent changed-test hangs

scripts/check-changed.mjs

@@ -10,6 +10,20 @@ import { printTimingSummary } from "./lib/check-timing-summary.mjs";
 import { runManagedCommand } from "./lib/managed-child-process.mjs";
 import { resolveChangedTestTargetPlan } from "./test-projects.test-support.mjs";
 
+export const CHANGED_CHECK_VITEST_NO_OUTPUT_TIMEOUT_MS = "60000";
+const VITEST_NO_OUTPUT_TIMEOUT_ENV_KEY = "OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS";
+const VITEST_NO_OUTPUT_RETRY_ENV_KEY = "OPENCLAW_VITEST_NO_OUTPUT_RETRY";
+
+export function createChangedCheckVitestEnv(baseEnv = process.env) {
+  return {
+    ...baseEnv,
+    [VITEST_NO_OUTPUT_TIMEOUT_ENV_KEY]:
+      baseEnv[VITEST_NO_OUTPUT_TIMEOUT_ENV_KEY]?.trim() ||
+      CHANGED_CHECK_VITEST_NO_OUTPUT_TIMEOUT_MS,
+    [VITEST_NO_OUTPUT_RETRY_ENV_KEY]: baseEnv[VITEST_NO_OUTPUT_RETRY_ENV_KEY]?.trim() || "0",
+  };
+}
+
 export function createChangedCheckPlan(result, options = {}) {
   const commands = [];
   const add = (name, args) => {
@@ -138,7 +152,10 @@ export async function runChangedCheck(result, options = {}) {
   }
 
   if (plan.runFullTests) {
-    const status = await runPnpm({ name: "tests all", args: ["test"] }, timings);
+    const status = await runPnpm(
+      { name: "tests all", args: ["test"], env: createChangedCheckVitestEnv() },
+      timings,
+    );
     if (status !== 0) {
       printSummary(timings, options);
       return status;
@@ -151,6 +168,7 @@ export async function runChangedCheck(result, options = {}) {
       {
         name: options.explicitPaths ? "tests all" : "tests changed broad",
         args: testArgs,
+        env: createChangedCheckVitestEnv(),
       },
       timings,
     );
@@ -163,6 +181,7 @@ export async function runChangedCheck(result, options = {}) {
       {
         name: "tests changed",
         args: ["test", ...plan.testTargets],
+        env: createChangedCheckVitestEnv(),
       },
       timings,
     );
@@ -173,7 +192,14 @@ export async function runChangedCheck(result, options = {}) {
   }
 
   if (plan.runExtensionTests) {
-    const status = await runPnpm({ name: "tests extensions", args: ["test:extensions"] }, timings);
+    const status = await runPnpm(
+      {
+        name: "tests extensions",
+        args: ["test:extensions"],
+        env: createChangedCheckVitestEnv(),
+      },
+      timings,
+    );
     if (status !== 0) {
       printSummary(timings, options);
       return status;
@@ -217,6 +243,7 @@ async function runCommand(command, timings) {
     status = await runManagedCommand({
       bin: command.bin,
       args: command.args,
+      env: command.env,
     });
   } catch (error) {
     console.error(error);

scripts/test-projects.mjs

@@ -20,6 +20,7 @@ import {
   resolveParallelFullSuiteConcurrency,
   resolveChangedTargetArgs,
   shouldAcquireLocalHeavyCheckLock,
+  shouldRetryVitestNoOutputTimeout,
   writeVitestIncludeFile,
 } from "./test-projects.test-support.mjs";
 
@@ -236,7 +237,7 @@ async function runLoggedVitestSpec(spec) {
   console.error(`[test] starting ${spec.config}`);
   const startedAt = performance.now();
   let result = await runVitestSpec(spec);
-  if (result.noOutputTimedOut && !spec.watchMode) {
+  if (result.noOutputTimedOut && !spec.watchMode && shouldRetryVitestNoOutputTimeout(spec.env)) {
     console.error(`[test] retrying ${spec.config} after no-output timeout`);
     result = await runVitestSpec(spec);
   }

scripts/test-projects.test-support.mjs

@@ -243,6 +243,7 @@ const GENERATED_CHANGED_TEST_TARGETS = new Set([
   "src/canvas-host/a2ui/a2ui.bundle.js",
 ]);
 const VITEST_NO_OUTPUT_TIMEOUT_ENV_KEY = "OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS";
+const VITEST_NO_OUTPUT_RETRY_ENV_KEY = "OPENCLAW_VITEST_NO_OUTPUT_RETRY";
 export const DEFAULT_TEST_PROJECTS_VITEST_NO_OUTPUT_TIMEOUT_MS = "180000";
 const VITEST_CONFIG_TARGET_KIND_BY_PATH = new Map(
   Object.entries(VITEST_CONFIG_BY_KIND).map(([kind, config]) => [config, kind]),
@@ -1098,6 +1099,11 @@ export function applyDefaultVitestNoOutputTimeout(specs, params = {}) {
   });
 }
 
+export function shouldRetryVitestNoOutputTimeout(env = process.env) {
+  const value = env[VITEST_NO_OUTPUT_RETRY_ENV_KEY]?.trim().toLowerCase();
+  return !["0", "false", "no", "off"].includes(value ?? "");
+}
+
 export function createVitestRunSpecs(args, params = {}) {
   const cwd = params.cwd ?? process.cwd();
   const baseEnv = params.baseEnv ?? process.env;

test/scripts/changed-lanes.test.ts

@@ -3,21 +3,41 @@ import { mkdirSync, writeFileSync } from "node:fs";
 import path from "node:path";
 import { afterEach, describe, expect, it } from "vitest";
 import { detectChangedLanes } from "../../scripts/changed-lanes.mjs";
-import { createChangedCheckPlan } from "../../scripts/check-changed.mjs";
+import {
+  CHANGED_CHECK_VITEST_NO_OUTPUT_TIMEOUT_MS,
+  createChangedCheckPlan,
+  createChangedCheckVitestEnv,
+} from "../../scripts/check-changed.mjs";
 import { cleanupTempDirs, makeTempRepoRoot } from "../helpers/temp-repo.js";
 
 const tempDirs: string[] = [];
 const repoRoot = process.cwd();
+const nestedGitEnvKeys = [
+  "GIT_ALTERNATE_OBJECT_DIRECTORIES",
+  "GIT_DIR",
+  "GIT_INDEX_FILE",
+  "GIT_OBJECT_DIRECTORY",
+  "GIT_QUARANTINE_PATH",
+  "GIT_WORK_TREE",
+] as const;
+
+function createNestedGitEnv(): NodeJS.ProcessEnv {
+  const env = {
+    ...process.env,
+    GIT_CONFIG_NOSYSTEM: "1",
+    GIT_TERMINAL_PROMPT: "0",
+  };
+  for (const key of nestedGitEnvKeys) {
+    delete env[key];
+  }
+  return env;
+}
 
 const git = (cwd: string, args: string[]) =>
   execFileSync("git", args, {
     cwd,
     encoding: "utf8",
-    env: {
-      ...process.env,
-      GIT_CONFIG_NOSYSTEM: "1",
-      GIT_TERMINAL_PROMPT: "0",
-    },
+    env: createNestedGitEnv(),
   }).trim();
 
 afterEach(() => {
@@ -50,11 +70,7 @@ describe("scripts/changed-lanes", () => {
       {
         cwd: dir,
         encoding: "utf8",
-        env: {
-          ...process.env,
-          GIT_CONFIG_NOSYSTEM: "1",
-          GIT_TERMINAL_PROMPT: "0",
-        },
+        env: createNestedGitEnv(),
       },
     );
 
@@ -238,6 +254,7 @@ describe("scripts/changed-lanes", () => {
         [path.join(repoRoot, "scripts", "check-release-metadata-only.mjs"), "--staged"],
         {
           cwd: dir,
+          env: createNestedGitEnv(),
           stdio: "pipe",
         },
       ),
@@ -255,6 +272,7 @@ describe("scripts/changed-lanes", () => {
         [path.join(repoRoot, "scripts", "check-release-metadata-only.mjs"), "--staged"],
         {
           cwd: dir,
+          env: createNestedGitEnv(),
           stdio: "pipe",
         },
       ),
@@ -344,4 +362,22 @@ describe("scripts/changed-lanes", () => {
     expect(plan.runChangedTestsBroad).toBe(false);
     expect(plan.runFullTests).toBe(false);
   });
+
+  it("sets a fail-fast Vitest watchdog for changed checks", () => {
+    expect(createChangedCheckVitestEnv({ PATH: "/usr/bin" })).toMatchObject({
+      PATH: "/usr/bin",
+      OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS: CHANGED_CHECK_VITEST_NO_OUTPUT_TIMEOUT_MS,
+      OPENCLAW_VITEST_NO_OUTPUT_RETRY: "0",
+    });
+
+    expect(
+      createChangedCheckVitestEnv({
+        OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS: "45000",
+        OPENCLAW_VITEST_NO_OUTPUT_RETRY: "1",
+      }),
+    ).toMatchObject({
+      OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS: "45000",
+      OPENCLAW_VITEST_NO_OUTPUT_RETRY: "1",
+    });
+  });
 });

test/scripts/test-projects.test.ts

@@ -12,6 +12,7 @@ import {
   resolveChangedTestTargetPlan,
   resolveChangedTargetArgs,
   resolveParallelFullSuiteConcurrency,
+  shouldRetryVitestNoOutputTimeout,
 } from "../../scripts/test-projects.test-support.mjs";
 
 describe("scripts/test-projects changed-target routing", () => {
@@ -873,6 +874,15 @@ describe("scripts/test-projects Vitest stall watchdog", () => {
     expect(specs[0]?.env.OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS).toBeUndefined();
     expect(specs[1]?.env.OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS).toBe("0");
   });
+
+  it("allows changed checks to disable automatic silent-run retries", () => {
+    expect(shouldRetryVitestNoOutputTimeout({})).toBe(true);
+    expect(shouldRetryVitestNoOutputTimeout({ OPENCLAW_VITEST_NO_OUTPUT_RETRY: "1" })).toBe(true);
+    expect(shouldRetryVitestNoOutputTimeout({ OPENCLAW_VITEST_NO_OUTPUT_RETRY: "0" })).toBe(false);
+    expect(shouldRetryVitestNoOutputTimeout({ OPENCLAW_VITEST_NO_OUTPUT_RETRY: "false" })).toBe(
+      false,
+    );
+  });
 });
 
 describe("scripts/test-projects Vitest cache isolation", () => {