Agents: harden session file repair

src/agents/session-file-repair.test.ts

@@ -1,7 +1,7 @@
 import fs from "node:fs/promises";
 import os from "node:os";
 import path from "node:path";
-import { describe, expect, it } from "vitest";
+import { describe, expect, it, vi } from "vitest";
 import { repairSessionFileIfNeeded } from "./session-file-repair.js";
 
 describe("repairSessionFileIfNeeded", () => {
@@ -39,4 +39,61 @@ describe("repairSessionFileIfNeeded", () => {
       expect(backup).toBe(content);
     }
   });
+
+  it("does not drop CRLF-terminated JSONL lines", async () => {
+    const dir = await fs.mkdtemp(path.join(os.tmpdir(), "openclaw-session-repair-"));
+    const file = path.join(dir, "session.jsonl");
+    const header = {
+      type: "session",
+      version: 7,
+      id: "session-1",
+      timestamp: new Date().toISOString(),
+      cwd: "/tmp",
+    };
+    const message = {
+      type: "message",
+      id: "msg-1",
+      parentId: null,
+      timestamp: new Date().toISOString(),
+      message: { role: "user", content: "hello" },
+    };
+    const content = `${JSON.stringify(header)}\r\n${JSON.stringify(message)}\r\n`;
+    await fs.writeFile(file, content, "utf-8");
+
+    const result = await repairSessionFileIfNeeded({ sessionFile: file });
+    expect(result.repaired).toBe(false);
+    expect(result.droppedLines).toBe(0);
+  });
+
+  it("warns and skips repair when the session header is invalid", async () => {
+    const dir = await fs.mkdtemp(path.join(os.tmpdir(), "openclaw-session-repair-"));
+    const file = path.join(dir, "session.jsonl");
+    const badHeader = {
+      type: "message",
+      id: "msg-1",
+      timestamp: new Date().toISOString(),
+      message: { role: "user", content: "hello" },
+    };
+    const content = `${JSON.stringify(badHeader)}\n{"type":"message"`;
+    await fs.writeFile(file, content, "utf-8");
+
+    const warn = vi.fn();
+    const result = await repairSessionFileIfNeeded({ sessionFile: file, warn });
+
+    expect(result.repaired).toBe(false);
+    expect(result.reason).toBe("invalid session header");
+    expect(warn).toHaveBeenCalledTimes(1);
+    expect(warn.mock.calls[0]?.[0]).toContain("invalid session header");
+  });
+
+  it("returns a detailed reason when read errors are not ENOENT", async () => {
+    const dir = await fs.mkdtemp(path.join(os.tmpdir(), "openclaw-session-repair-"));
+    const warn = vi.fn();
+
+    const result = await repairSessionFileIfNeeded({ sessionFile: dir, warn });
+
+    expect(result.repaired).toBe(false);
+    expect(result.reason).toContain("failed to read session file");
+    expect(warn).toHaveBeenCalledTimes(1);
+  });
 });

src/agents/session-file-repair.ts

@@ -28,11 +28,17 @@ export async function repairSessionFileIfNeeded(params: {
   let content: string;
   try {
     content = await fs.readFile(sessionFile, "utf-8");
-  } catch {
+  } catch (err) {
-    return { repaired: false, droppedLines: 0, reason: "missing session file" };
+    const code = (err as { code?: unknown } | undefined)?.code;
+    if (code === "ENOENT") {
+      return { repaired: false, droppedLines: 0, reason: "missing session file" };
+    }
+    const reason = `failed to read session file: ${err instanceof Error ? err.message : "unknown error"}`;
+    params.warn?.(`session file repair skipped: ${reason} (${path.basename(sessionFile)})`);
+    return { repaired: false, droppedLines: 0, reason };
   }
 
-  const lines = content.split("\n");
+  const lines = content.split(/\r?\n/);
   const entries: unknown[] = [];
   let droppedLines = 0;
 
@@ -53,6 +59,9 @@ export async function repairSessionFileIfNeeded(params: {
   }
 
   if (!isSessionHeader(entries[0])) {
+    params.warn?.(
+      `session file repair skipped: invalid session header (${path.basename(sessionFile)})`,
+    );
     return { repaired: false, droppedLines, reason: "invalid session header" };
   }
 
@@ -77,8 +86,12 @@ export async function repairSessionFileIfNeeded(params: {
   } catch (err) {
     try {
       await fs.unlink(tmpPath);
-    } catch {
+    } catch (cleanupErr) {
-      // ignore cleanup failures
+      params.warn?.(
+        `session file repair cleanup failed: ${cleanupErr instanceof Error ? cleanupErr.message : "unknown error"} (${path.basename(
+          tmpPath,
+        )})`,
+      );
     }
     return {
       repaired: false,