fix(quality-gates): fail coderabbit on non-zero exit

Fixes #763 and #764. Validated with full CI, CodeRabbit, manifest, Jest matrix, typecheck, lint, and local targeted/full tests.

Author: rafaelscosta

.aiox-core/core/orchestration/workflow-executor.js

@@ -804,7 +804,7 @@ class WorkflowExecutor {
               '`wsl --install` (https://learn.microsoft.com/windows/wsl/install), ' +
               'then install the CodeRabbit CLI inside the WSL distribution. ' +
               'See docs/guides/installation-troubleshooting.md Issue 10. ' +
-              `To bypass this check, set coderabbit.installation_mode='native' in your config.`
+              'To bypass this check, set coderabbit.installation_mode=\'native\' in your config.',
           );
         }
         const wslPath = this.projectRoot
@@ -829,7 +829,7 @@ class WorkflowExecutor {
       });
 
       // Parse CodeRabbit output to extract issues
-      const issues = this.parseCodeRabbitOutput(stdout);
+      const issues = this.parseCodeRabbitOutput([stdout || '', stderr || ''].join('\n'));
 
       return {
         success: true,
@@ -845,6 +845,16 @@ class WorkflowExecutor {
           issues: [],
         };
       }
+      if (error.code !== undefined && error.code !== 0) {
+        return {
+          success: false,
+          error:
+            `CodeRabbit CLI exited with code ${error.code}. ` +
+            `stdout: ${(error.stdout || '').slice(0, 200)}, ` +
+            `stderr: ${(error.stderr || '').slice(0, 200)}`,
+          issues: [],
+        };
+      }
       return {
         success: false,
         error: error.message,

.aiox-core/core/quality-gates/layer2-pr-automation.js

@@ -147,6 +147,13 @@ class Layer2PRAutomation extends BaseLayer {
       }
 
       const result = await this.runCommand(command, timeout);
+      if (result.exitCode !== undefined && result.exitCode !== 0) {
+        throw new Error(
+          `CodeRabbit CLI exited with code ${result.exitCode}. ` +
+            `stdout: ${(result.stdout || '').slice(0, 200)}, ` +
+            `stderr: ${(result.stderr || '').slice(0, 200)}`,
+        );
+      }
 
       // Parse CodeRabbit output for issues
       const issues = this.parseCodeRabbitOutput(result.stdout + result.stderr);

.aiox-core/install-manifest.yaml

@@ -8,7 +8,7 @@
 # - File types for categorization
 #
 version: 5.2.7
-generated_at: "2026-05-18T11:40:45.332Z"
+generated_at: "2026-05-18T15:42:34.055Z"
 generator: scripts/generate-install-manifest.js
 file_count: 1128
 files:
@@ -989,9 +989,9 @@ files:
     type: core
     size: 31469
   - path: core/orchestration/workflow-executor.js
-    hash: sha256:5bc1c72b7565f3ae5794d4d379d2090c605ca6c383ebbb94a042c5f96b2b9102
+    hash: sha256:8c56facc975f0452d686183d25ab1c19211afd127814b2ade963b4950352872f
     type: core
-    size: 38289
+    size: 38673
   - path: core/orchestration/workflow-orchestrator.js
     hash: sha256:82816bd5e6fecc9bbb77292444e53254c72bf93e5c04260784743354c6a58627
     type: core
@@ -1037,9 +1037,9 @@ files:
     type: core
     size: 9393
   - path: core/quality-gates/layer2-pr-automation.js
-    hash: sha256:19e52369efe5cf0df9d0b6a9675dd555fdd46c1ab19cf6dc45d9173ad6e6524e
+    hash: sha256:40a7b03d6294c79741e9313ae91a8d6a30797dca1df4e3ca406edfe2911b4322
     type: core
-    size: 11907
+    size: 12213
   - path: core/quality-gates/layer3-human-review.js
     hash: sha256:9bf79d5adfddae55d7dddfda777cd2775aa76f82204ddd0f660f6edbd093b16b
     type: core

tests/core/orchestration/workflow-executor-coderabbit.test.js

@@ -0,0 +1,134 @@
+/**
+ * WorkflowExecutor CodeRabbit invocation tests
+ *
+ * Regression guards for #763/#764:
+ * - non-zero CodeRabbit subprocess exits must not pass silently
+ * - workflow-executor WSL probing mirrors Layer 2 behavior
+ */
+
+'use strict';
+
+const childProcess = require('child_process');
+const os = require('os');
+const path = require('path');
+
+const { WorkflowExecutor } = require('../../../.aiox-core/core/orchestration/workflow-executor');
+
+const expectedDefaultCliPath = path.join(os.homedir(), '/.local/bin/coderabbit');
+
+describe('WorkflowExecutor CodeRabbit analysis', () => {
+  let originalPlatform;
+  let spawnSyncSpy;
+  let execSpy;
+
+  beforeEach(() => {
+    originalPlatform = process.platform;
+    spawnSyncSpy = jest.spyOn(childProcess, 'spawnSync').mockImplementation((cmd) => {
+      if (cmd === 'wsl') {
+        return { status: 0, stdout: 'Ubuntu\n', stderr: '' };
+      }
+      return { status: 0, stdout: '', stderr: '' };
+    });
+    execSpy = jest.spyOn(childProcess, 'exec').mockImplementation((command, options, callback) => {
+      callback(null, '', '');
+      return { pid: 1234 };
+    });
+  });
+
+  afterEach(() => {
+    Object.defineProperty(process, 'platform', { value: originalPlatform });
+    spawnSyncSpy.mockRestore();
+    execSpy.mockRestore();
+  });
+
+  const setPlatform = (value) => {
+    Object.defineProperty(process, 'platform', { value });
+  };
+
+  const runAnalysis = (config = {}, projectRoot = process.cwd()) => {
+    const executor = new WorkflowExecutor(projectRoot, { saveState: false, debug: false });
+    return executor.runCodeRabbitAnalysis({
+      self_healing: { timeout_minutes: 1 },
+      ...config,
+    });
+  };
+
+  it('returns an informative failure when CodeRabbit exits non-zero', async () => {
+    setPlatform('darwin');
+    execSpy.mockImplementation((command, options, callback) => {
+      const error = new Error('Command failed');
+      error.code = 137;
+      error.stdout = '';
+      error.stderr = '';
+      callback(error, '', '');
+      return { pid: 1234 };
+    });
+
+    const result = await runAnalysis({ installation_mode: 'native' });
+
+    expect(result.success).toBe(false);
+    expect(result.error).toMatch(/CodeRabbit CLI exited with code 137/);
+    expect(result.error).toContain('stdout:');
+    expect(result.error).toContain('stderr:');
+  });
+
+  it('surfaces a clear error when WSL binary is missing (ENOENT)', async () => {
+    setPlatform('darwin');
+    spawnSyncSpy.mockImplementation((cmd) => {
+      if (cmd === 'wsl') {
+        return { error: Object.assign(new Error('ENOENT'), { code: 'ENOENT' }), status: null };
+      }
+      return { status: 0, stdout: '', stderr: '' };
+    });
+
+    const result = await runAnalysis({ installation_mode: 'wsl' });
+
+    expect(spawnSyncSpy).toHaveBeenCalledWith('wsl', ['-l'], expect.any(Object));
+    expect(result.success).toBe(false);
+    expect(result.error).toMatch(/CodeRabbit CLI requires WSL/);
+    expect(result.error).toMatch(/wsl --install/);
+    expect(result.error).toMatch(/installation-troubleshooting/);
+    expect(execSpy).not.toHaveBeenCalled();
+  });
+
+  it('surfaces a clear error when WSL has no usable distribution', async () => {
+    setPlatform('darwin');
+    spawnSyncSpy.mockImplementation((cmd) => {
+      if (cmd === 'wsl') {
+        return { status: 1, stdout: '', stderr: 'no distros\n' };
+      }
+      return { status: 0, stdout: '', stderr: '' };
+    });
+
+    const result = await runAnalysis({ installation_mode: 'wsl' });
+
+    expect(spawnSyncSpy).toHaveBeenCalledWith('wsl', ['-l'], expect.any(Object));
+    expect(result.success).toBe(false);
+    expect(result.error).toMatch(/CodeRabbit CLI requires WSL/);
+    expect(execSpy).not.toHaveBeenCalled();
+  });
+
+  it('does not probe WSL when installation_mode=native on Windows', async () => {
+    setPlatform('win32');
+
+    await runAnalysis({ installation_mode: 'native' });
+
+    expect(execSpy).toHaveBeenCalled();
+    const command = execSpy.mock.calls[0][0];
+    expect(command).toBe(`${expectedDefaultCliPath} --prompt-only -t uncommitted`);
+    const wslProbeCalls = spawnSyncSpy.mock.calls.filter((c) => c[0] === 'wsl');
+    expect(wslProbeCalls).toHaveLength(0);
+  });
+
+  it('does not probe WSL for default native mode on macOS', async () => {
+    setPlatform('darwin');
+
+    await runAnalysis();
+
+    expect(execSpy).toHaveBeenCalled();
+    const command = execSpy.mock.calls[0][0];
+    expect(command).toBe(`${expectedDefaultCliPath} --prompt-only -t uncommitted`);
+    const wslProbeCalls = spawnSyncSpy.mock.calls.filter((c) => c[0] === 'wsl');
+    expect(wslProbeCalls).toHaveLength(0);
+  });
+});

tests/unit/quality-gates/layer2-pr-automation.test.js

@@ -127,6 +127,22 @@ describe('Layer2PRAutomation', () => {
       expect(result.skipped).toBe(true);
       expect(result.message).toContain('not installed');
     });
+
+    it('should fail when CodeRabbit exits non-zero even without output', async () => {
+      layer.runCommand = jest.fn().mockResolvedValue({
+        exitCode: 137,
+        stdout: '',
+        stderr: '',
+        duration: 100,
+      });
+
+      const result = await layer.runCodeRabbit();
+
+      expect(result.pass).toBe(false);
+      expect(result.error).toMatch(/CodeRabbit CLI exited with code 137/);
+      expect(result.error).toContain('stdout:');
+      expect(result.error).toContain('stderr:');
+    });
   });
 
   describe('runQuinnReview', () => {