fix(cli): clean orphaned managed npm update artifacts

packages/cli/src/utils/managed-npm-update.test.ts

@@ -347,4 +347,100 @@ describe('managed npm update', () => {
 
     expect(fs.existsSync(update.stagingDir)).toBe(false);
   });
+
+  it('removes only orphaned managed update artifacts before staging', () => {
+    const root = makeTemporaryDirectory();
+    const bootstrap = writeBaseInstallation(root);
+    const updateRoot = path.join(root, 'updates');
+    const current = prepareManagedNpmUpdate('2.0.0', bootstrap, updateRoot);
+    const versionsDir = path.dirname(current.stagingDir);
+    const missingPid = 999999999;
+    const staleStagingDir = fs.mkdtempSync(
+      path.join(versionsDir, `.2.1.0-${missingPid}-`),
+    );
+    const staleActiveFile = path.join(
+      current.launcherRoot,
+      `active.json.${missingPid}`,
+    );
+    const activeStagingDir = fs.mkdtempSync(
+      path.join(versionsDir, `.2.2.0-${process.pid}-`),
+    );
+    const activeTemporaryFile = path.join(
+      current.launcherRoot,
+      `active.json.${process.pid}`,
+    );
+    const versionDir = path.join(versionsDir, '1.0.0');
+    const unknownDir = path.join(versionsDir, 'unrelated');
+    const nonSemverDir = path.join(
+      versionsDir,
+      `.not-semver-${missingPid}-abc123`,
+    );
+    const stagingSymlink = path.join(
+      versionsDir,
+      `.2.3.0-${missingPid}-abcdef`,
+    );
+    fs.writeFileSync(staleActiveFile, 'stale');
+    fs.writeFileSync(activeTemporaryFile, 'active');
+    fs.mkdirSync(versionDir);
+    fs.mkdirSync(unknownDir);
+    fs.mkdirSync(nonSemverDir);
+    fs.symlinkSync(
+      versionDir,
+      stagingSymlink,
+      process.platform === 'win32' ? 'junction' : 'dir',
+    );
+    const kill = vi.spyOn(process, 'kill').mockImplementation((pid) => {
+      if (pid === missingPid) {
+        const error = new Error('process not found') as NodeJS.ErrnoException;
+        error.code = 'ESRCH';
+        throw error;
+      }
+      return true;
+    });
+    try {
+      prepareManagedNpmUpdate('3.0.0', bootstrap, updateRoot);
+
+      expect(fs.existsSync(staleStagingDir)).toBe(false);
+      expect(fs.existsSync(staleActiveFile)).toBe(false);
+      expect(fs.existsSync(current.stagingDir)).toBe(true);
+      expect(fs.existsSync(activeStagingDir)).toBe(true);
+      expect(fs.existsSync(activeTemporaryFile)).toBe(true);
+      expect(fs.existsSync(versionDir)).toBe(true);
+      expect(fs.existsSync(unknownDir)).toBe(true);
+      expect(fs.existsSync(nonSemverDir)).toBe(true);
+      expect(fs.existsSync(stagingSymlink)).toBe(true);
+    } finally {
+      kill.mockRestore();
+    }
+  });
+
+  it('keeps artifacts when process liveness is uncertain', () => {
+    const root = makeTemporaryDirectory();
+    const bootstrap = writeBaseInstallation(root);
+    const updateRoot = path.join(root, 'updates');
+    const current = prepareManagedNpmUpdate('2.0.0', bootstrap, updateRoot);
+    const versionsDir = path.dirname(current.stagingDir);
+    const inaccessiblePid = 888888888;
+    const stagingDir = fs.mkdtempSync(
+      path.join(versionsDir, `.2.1.0-${inaccessiblePid}-`),
+    );
+    const temporaryActiveFile = path.join(
+      current.launcherRoot,
+      `active.json.${inaccessiblePid}`,
+    );
+    fs.writeFileSync(temporaryActiveFile, 'unverified');
+    const kill = vi.spyOn(process, 'kill').mockImplementation(() => {
+      const error = new Error('permission denied') as NodeJS.ErrnoException;
+      error.code = 'EPERM';
+      throw error;
+    });
+    try {
+      prepareManagedNpmUpdate('3.0.0', bootstrap, updateRoot);
+
+      expect(fs.existsSync(stagingDir)).toBe(true);
+      expect(fs.existsSync(temporaryActiveFile)).toBe(true);
+    } finally {
+      kill.mockRestore();
+    }
+  });
 });

packages/cli/src/utils/managed-npm-update.ts

@@ -48,6 +48,68 @@ function launcherId(bootstrapPath: string): string {
   return createHash('sha256').update(bootstrapPath).digest('hex').slice(0, 16);
 }
 
+function processDoesNotExist(pidText: string): boolean {
+  const pid = Number(pidText);
+  if (!Number.isSafeInteger(pid)) return false;
+  try {
+    process.kill(pid, 0);
+    return false;
+  } catch (error) {
+    return (error as NodeJS.ErrnoException).code === 'ESRCH';
+  }
+}
+
+function readDirectoryEntries(directory: string): fs.Dirent[] {
+  try {
+    return fs.readdirSync(directory, { withFileTypes: true });
+  } catch {
+    return [];
+  }
+}
+
+function cleanupOrphanedManagedNpmUpdateArtifacts(
+  launcherRoot: string,
+  versionsDir: string,
+): void {
+  for (const entry of readDirectoryEntries(versionsDir)) {
+    const match = /^\.(.+)-([1-9]\d*)-[A-Za-z0-9]{6}$/.exec(entry.name);
+    if (
+      !entry.isDirectory() ||
+      entry.isSymbolicLink() ||
+      !match ||
+      semver.valid(match[1]) !== match[1] ||
+      !processDoesNotExist(match[2])
+    ) {
+      continue;
+    }
+    try {
+      fs.rmSync(path.join(versionsDir, entry.name), {
+        recursive: true,
+        force: true,
+      });
+    } catch {
+      continue;
+    }
+  }
+
+  for (const entry of readDirectoryEntries(launcherRoot)) {
+    const match = /^active\.json\.([1-9]\d*)$/.exec(entry.name);
+    if (
+      !entry.isFile() ||
+      entry.isSymbolicLink() ||
+      !match ||
+      !processDoesNotExist(match[1])
+    ) {
+      continue;
+    }
+    try {
+      fs.rmSync(path.join(launcherRoot, entry.name), { force: true });
+    } catch {
+      continue;
+    }
+  }
+}
+
 function resolveNpmGlobalConfigPath(): string {
   const configured = process.env['NPM_CONFIG_GLOBALCONFIG'];
   if (configured) return path.resolve(configured);
@@ -156,6 +218,7 @@ export function prepareManagedNpmUpdate(
   const launcherRoot = path.join(updateRoot, launcherId(resolvedBootstrapPath));
   const versionsDir = path.join(launcherRoot, 'versions');
   fs.mkdirSync(versionsDir, { recursive: true });
+  cleanupOrphanedManagedNpmUpdateArtifacts(launcherRoot, versionsDir);
   const stagingDir = fs.mkdtempSync(
     path.join(versionsDir, `.${version}-${process.pid}-`),
   );