fix(start): emit boot-sibling chunks as scripts for IIFE entries

.changeset/seven-times-pump.md

@@ -0,0 +1,6 @@
+---
+'@tanstack/start-plugin-core': patch
+'@tanstack/start-server-core': patch
+---
+
+fix(start): emit client entry scripts from the root route manifest. When `scriptFormat: 'iife'` and the entry chunk has static-import siblings (e.g. an extracted runtime via `optimization.runtimeChunk: 'single'`), the manifest now includes those async siblings before the async client entry in root route scripts, fixing hydration for IIFE bundles with extracted runtimes.

e2e/react-start/custom-server-rsbuild/rsbuild.config.ts

@@ -1,10 +1,65 @@
+import path from 'node:path'
 import { defineConfig } from '@rsbuild/core'
 import { pluginReact } from '@rsbuild/plugin-react'
 import { tanstackStart } from '@tanstack/react-start/plugin/rsbuild'
 
+// Stress-test fixture for `<Scripts />` and the start manifest under a
+// non-default client chunk layout. The combination that matters for the
+// repro is:
+//
+//   - `client.output: 'iife'` — emit the client entry as a self-executing
+//     script. The manifest uses plain script tags and classic script preloads;
+//     setting IIFE here exercises that non-module asset path.
+//
+//   - Client `runtimeChunk: 'single'` — extracts the webpack runtime into
+//     its own chunk. With IIFE plain scripts, the entry can't bootstrap
+//     until the runtime has executed, so `<Scripts />` has to emit a
+//     `<script>` for the runtime chunk (not just a preload). This was
+//     the regression this fixture covers.
+//
+//   - `client.distPath.root` + `distPath.js: ''` — flat layout, JS at the
+//     dist root. Matches the path `express-server.ts` serves via
+//     `express.static('dist/client')`.
+//
+//   - `performance.buildCache: true` — exercise the rspack persistent
+//     cache, including warm-restart paths.
+//
+//   - `output.assetPrefix: '/static/'` — force manifest URLs through an
+//     explicit prefix.
 export default defineConfig({
   plugins: [
-    pluginReact({ splitChunks: false }),
-    tanstackStart({ rsbuild: { installDevServerMiddleware: false } }),
+    pluginReact(),
+    tanstackStart({
+      rsbuild: {
+        installDevServerMiddleware: false,
+        client: {
+          output: 'iife',
+        },
+      },
+    }),
   ],
+  performance: {
+    buildCache: true,
+  },
+  output: {
+    assetPrefix: '/static/',
+  },
+  environments: {
+    client: {
+      output: {
+        distPath: {
+          root: path.resolve(__dirname, 'dist/client'),
+          js: '',
+        },
+      },
+      tools: {
+        rspack: (config) => {
+          config.optimization = {
+            ...(config.optimization ?? {}),
+            runtimeChunk: 'single',
+          }
+        },
+      },
+    },
+  },
 })

packages/start-plugin-core/src/rsbuild/virtual-modules.ts

@@ -72,14 +72,27 @@ function getScriptFormatProperty(scriptFormat: ScriptFormat): string {
   return scriptFormat === 'iife' ? `  scriptFormat: 'iife',\n` : ''
 }
 
+function getEntryScriptAttrs(
+  entryUrl: string,
+  scriptFormat: ScriptFormat,
+): string {
+  return scriptFormat === 'module'
+    ? `{ type: 'module', async: true, src: '${entryUrl}' }`
+    : `{ async: true, src: '${entryUrl}' }`
+}
+
 function generateManifestModuleDev(
   devClientEntryUrl: string,
   scriptFormat: ScriptFormat,
 ): string {
   const scriptFormatProperty = getScriptFormatProperty(scriptFormat)
   return `const fallbackManifest = {
-${scriptFormatProperty}  routes: {},
-  clientEntry: '${devClientEntryUrl}',
+${scriptFormatProperty}  routes: {
+    __root__: {
+      preloads: ['${devClientEntryUrl}'],
+      scripts: [{ attrs: ${getEntryScriptAttrs(devClientEntryUrl, scriptFormat)} }],
+    },
+  },
 }
 export const tsrStartManifest = () => globalThis[${JSON.stringify(DEV_START_MANIFEST_GLOBAL)}] ?? fallbackManifest`
 }

packages/start-plugin-core/src/start-manifest-plugin/manifestBuilder.ts

@@ -7,11 +7,6 @@ import {
   resolveManifestCssLink,
   rootRouteId,
 } from '@tanstack/router-core'
-import {
-  getRouteFilePathsFromModuleIds,
-  normalizeViteClientBuild,
-  normalizeViteClientChunk,
-} from '../vite/start-manifest-plugin/normalized-client-build'
 import { processInlineCssUrls } from './inlineCss'
 import type {
   ManifestAssetLink,
@@ -58,7 +53,6 @@ type DedupeRoute = {
 export interface StartManifest {
   scriptFormat?: ScriptFormat
   routes: Record<string, RouteTreeRoute>
-  clientEntry: string
   inlineCss?: {
     styles: Record<string, string>
     templates?: Record<string, InlineCssTemplate>
@@ -187,6 +181,56 @@ function appendRouteStylesheets(
   route.css = appendUniqueStylesheets(route.css, stylesheets)
 }
 
+function appendRouteScripts(
+  route: RouteTreeRoute,
+  scripts: Array<ManifestScript>,
+) {
+  if (scripts.length === 0) {
+    return
+  }
+
+  route.scripts = [...(route.scripts ?? []), ...scripts]
+}
+
+function buildScript(src: string, scriptFormat: ScriptFormat): ManifestScript {
+  return {
+    attrs: {
+      ...(scriptFormat === 'module' ? { type: 'module' } : {}),
+      async: true,
+      src,
+    },
+  }
+}
+
+function appendEntryChunkScripts(options: {
+  route: RouteTreeRoute
+  chunk: NormalizedClientChunk
+  scriptFormat: ScriptFormat
+  getAssetPath: (fileName: string) => string
+}) {
+  const scripts: Array<ManifestScript> = []
+
+  if (options.scriptFormat === 'iife') {
+    for (let i = 0; i < options.chunk.imports.length; i++) {
+      scripts.push(
+        buildScript(
+          options.getAssetPath(options.chunk.imports[i]!),
+          options.scriptFormat,
+        ),
+      )
+    }
+  }
+
+  scripts.push(
+    buildScript(
+      options.getAssetPath(options.chunk.fileName),
+      options.scriptFormat,
+    ),
+  )
+
+  appendRouteScripts(options.route, scripts)
+}
+
 function appendAdditionalRouteEntries(
   route: RouteTreeRoute,
   entries: ReadonlyArray<AdditionalRouteManifestEntry>,
@@ -207,9 +251,7 @@ function appendAdditionalRouteEntries(
   }
 
   appendRouteStylesheets(route, stylesheets)
-  if (scripts.length > 0) {
-    route.scripts = [...(route.scripts ?? []), ...scripts]
-  }
+  appendRouteScripts(route, scripts)
 }
 
 export function buildStartManifest(options: {
@@ -234,6 +276,13 @@ export function buildStartManifest(options: {
     additionalRouteAssets: options.additionalRouteAssets,
   })
 
+  appendEntryChunkScripts({
+    route: routes[rootRouteId]!,
+    chunk: scannedChunks.entryChunk,
+    scriptFormat: options.scriptFormat ?? 'module',
+    getAssetPath: assetResolvers.getAssetPath,
+  })
+
   dedupeNestedRouteManifestEntries(rootRouteId, routes[rootRouteId]!, routes)
 
   // Prune routes with no manifest data
@@ -249,7 +298,6 @@ export function buildStartManifest(options: {
 
   const result: StartManifest = {
     routes,
-    clientEntry: assetResolvers.getAssetPath(scannedChunks.entryChunk.fileName),
   }
 
   if (options.scriptFormat === 'iife') {
@@ -504,7 +552,7 @@ export function buildRouteManifestRoutes(options: {
   for (const [routeId, route] of Object.entries(options.routeTreeRoutes)) {
     if (!route.filePath) {
       if (routeId === rootRouteId) {
-        routes[routeId] = route
+        routes[routeId] = { ...route }
         continue
       }
 
@@ -513,7 +561,7 @@ export function buildRouteManifestRoutes(options: {
 
     const chunks = options.routeChunksByFilePath.get(route.filePath)
     if (!chunks) {
-      routes[routeId] = route
+      routes[routeId] = { ...route }
       continue
     }
 
@@ -634,12 +682,6 @@ function mergeReachableHydrationChunkData(options: {
   visitStaticChunk(options.chunk)
 }
 
-export {
-  getRouteFilePathsFromModuleIds,
-  normalizeViteClientBuild,
-  normalizeViteClientChunk,
-}
-
 function dedupeNestedRouteManifestEntries(
   routeId: string,
   route: DedupeRoute,

packages/start-plugin-core/src/vite/start-manifest-plugin/plugin.ts

@@ -5,12 +5,12 @@ import { DEV_CLIENT_ENTRY, START_ENVIRONMENT_NAMES } from '../../constants'
 import {
   buildStartManifest,
   createManifestAssetResolvers,
-  normalizeViteClientBuild,
   serializeStartManifest,
 } from '../../start-manifest-plugin/manifestBuilder'
 import { createVirtualModule } from '../createVirtualModule'
 import type { GetConfigFn, NormalizedClientBuild } from '../../types'
 import type { PluginOption, Rollup } from 'vite'
+import { normalizeViteClientBuild } from './normalized-client-build'
 
 type StartManifestEnvironment = {
   config: {
@@ -137,8 +137,12 @@ function getAssetFileNameByName(
 
 function getEmptyStartManifestModule(clientEntry: string) {
   return `export const tsrStartManifest = () => ({
-      routes: {},
-      clientEntry: '${clientEntry}',
+      routes: {
+        __root__: {
+          preloads: ['${clientEntry}'],
+          scripts: [{ attrs: { type: 'module', async: true, src: '${clientEntry}' } }],
+        },
+      },
     })`
 }
 

packages/start-plugin-core/tests/start-manifest-plugin.test.ts

@@ -12,13 +12,13 @@ vi.mock('@tanstack/start-server-core', () => ({
 describe('startManifestPlugin', () => {
   test('uses the virtual client entry during unbundled dev', () => {
     expect(loadDevManifest({ bundledDev: false })).toContain(
-      `clientEntry: '/@id/${DEV_CLIENT_ENTRY}'`,
+      `src: '/@id/${DEV_CLIENT_ENTRY}'`,
     )
   })
 
   test('uses the bundled client entry during bundled dev', () => {
     expect(loadDevManifest({ bundledDev: true })).toContain(
-      `clientEntry: '/assets/index.js'`,
+      `src: '/assets/index.js'`,
     )
   })
 })