fix: harden pi management verification

backend/test/pi-management.test.ts

@@ -1,7 +1,7 @@
 import { mkdtempSync, readFileSync, readdirSync, rmSync } from "node:fs";
 import { tmpdir } from "node:os";
 import { join } from "node:path";
-import { expect, test } from "vitest";
+import { expect, test, vi } from "vitest";
 import { loadConfig } from "../src/config.js";
 import {
   PiManagementError,
@@ -140,12 +140,95 @@ test("smoke uses the configured timeout and reports a sanitized timeout", async
   expect(calls).toEqual([{ command: "/usr/local/bin/pi", args: ["--version"], timeout: 750 }]);
 });
 
+// Catches a smoke endpoint that validates only the Pi binary/model catalogue and never makes a
+// request through the configured provider and model.
+test("smoke exercises the configured provider and model", async () => {
+  const providerChecks: unknown[] = [];
+  const service = createPiManagement(configFor(), {
+    execute: successfulExec([]),
+    listModels: async () => supportedModels,
+    readSettings: () => ({ provider: "zai", model: "glm-5.2", thinking: "medium" }),
+    smokeProvider: async (request) => { providerChecks.push(request); },
+    now: () => new Date("2026-08-05T10:00:00.000Z"),
+  });
+
+  await expect(service.test()).resolves.toEqual({
+    ready: true,
+    checkedAt: "2026-08-05T10:00:00.000Z",
+  });
+  expect(providerChecks).toEqual([{
+    provider: "zai", model: "glm-5.2", reasoning: "medium", timeoutMs: expect.any(Number),
+  }]);
+});
+
+// Catches expired provider credentials being treated as ready or raw provider diagnostics being
+// reflected through the management API.
+test("smoke fails closed and sanitizes configured-provider authentication errors", async () => {
+  const service = createPiManagement(configFor(), {
+    execute: successfulExec([]),
+    listModels: async () => supportedModels,
+    readSettings: () => ({ provider: "zai", model: "glm-5.2", thinking: "medium" }),
+    smokeProvider: async () => {
+      throw new Error('401 {"token":"raw-expired-token","output":"raw-provider-output"}');
+    },
+    now: () => new Date("2026-08-05T10:00:00.000Z"),
+  });
+
+  const result = await service.test();
+  expect(result).toEqual({
+    ready: false,
+    message: "Pi provider smoke check failed",
+    checkedAt: "2026-08-05T10:00:00.000Z",
+  });
+  expect(JSON.stringify(result)).not.toMatch(/raw-expired-token|raw-provider-output/);
+});
+
+// Catches separate per-phase timeouts that allow a later provider turn to exceed the one
+// end-to-end Pi Management smoke budget.
+test("smoke applies one deadline across version and a hung provider turn", async () => {
+  vi.useFakeTimers();
+  vi.setSystemTime(new Date("2026-08-05T10:00:00.000Z"));
+  try {
+    const providerTimeouts: number[] = [];
+    const service = createPiManagement(configFor(), {
+      execute: async () => await new Promise((resolve) => setTimeout(
+        () => resolve({ stdout: "pi 0.80.3\n", stderr: "" }),
+        500,
+      )),
+      listModels: async () => supportedModels,
+      readSettings: () => ({ provider: "zai", model: "glm-5.2", thinking: "medium" }),
+      smokeProvider: async ({ timeoutMs }) => {
+        providerTimeouts.push(timeoutMs);
+        await new Promise(() => {});
+      },
+      now: () => new Date("2026-08-05T10:00:00.000Z"),
+    });
+
+    let settled = false;
+    const pending = service.test().finally(() => { settled = true; });
+    await vi.advanceTimersByTimeAsync(500);
+    expect(providerTimeouts).toEqual([250]);
+    await vi.advanceTimersByTimeAsync(249);
+    expect(settled).toBe(false);
+    await vi.advanceTimersByTimeAsync(1);
+    await expect(pending).resolves.toEqual({
+      ready: false,
+      message: "Pi smoke check timed out",
+      checkedAt: "2026-08-05T10:00:00.000Z",
+    });
+  } finally {
+    vi.useRealTimers();
+  }
+});
+
 // Catches an unbounded diagnostics endpoint or one that returns bearer tokens and connection
 // passwords captured in Pi output.
 test("logs keep only the latest 200 redacted lines", async () => {
   const source = Array.from({ length: 205 }, (_, index) => `line-${index + 1}`);
   source[203] = "Authorization: Bearer raw-bearer-token";
   source[204] = "database_url=postgres://thoth:raw-db-password@example.invalid/db";
+  source[202] = '{"token":"raw-json-secret","password":"raw-json-password"}';
+  source[201] = "THT_MODEL_API_KEY=raw-env-secret";
   const service = createPiManagement(configFor(), {
     execute: successfulExec([]),
     listModels: async () => supportedModels,
@@ -159,5 +242,8 @@ test("logs keep only the latest 200 redacted lines", async () => {
   expect(logs.lines[0]).toBe("line-6");
   expect(logs.lines.join("\n")).not.toContain("raw-bearer-token");
   expect(logs.lines.join("\n")).not.toContain("raw-db-password");
+  expect(logs.lines.join("\n")).not.toContain("raw-json-secret");
+  expect(logs.lines.join("\n")).not.toContain("raw-json-password");
+  expect(logs.lines.join("\n")).not.toContain("raw-env-secret");
   expect(logs.lines.join("\n")).toContain("[REDACTED]");
 });