fix: report maestro ios runner setup failures

Author: thymikee

.github/workflows/ios.yml

@@ -30,6 +30,7 @@ jobs:
       IOS_RUNTIME_VERSION: '26.2'
       AGENT_DEVICE_STATE_DIR: ${{ github.workspace }}/.tmp/agent-device-state
       AGENT_DEVICE_IOS_RUNNER_DERIVED_PATH: ${{ github.workspace }}/.tmp/ios-runner-derived
+      AGENT_DEVICE_IOS_PREPARE_TIMEOUT_MS: '420000'
     steps:
       - name: Checkout
         uses: actions/checkout@de0fac2e4500dabe0009e67214ff5f5447ce83dd # v6.0.2
@@ -57,7 +58,7 @@ jobs:
       - name: Prepare iOS runner
         run: |
           pnpm clean:daemon
-          node --experimental-strip-types src/bin.ts prepare ios-runner --platform ios --timeout 300000 --json
+          node --experimental-strip-types src/bin.ts prepare ios-runner --platform ios --timeout "$AGENT_DEVICE_IOS_PREPARE_TIMEOUT_MS" --json
           pnpm clean:daemon
 
       - name: Run iOS simulator smoke replay

.github/workflows/perf-nightly.yml

@@ -36,6 +36,7 @@ jobs:
       IOS_RUNTIME_VERSION: "26.2"
       AGENT_DEVICE_STATE_DIR: ${{ github.workspace }}/.tmp/agent-device-state
       AGENT_DEVICE_IOS_RUNNER_DERIVED_PATH: ${{ github.workspace }}/.tmp/ios-runner-derived
+      AGENT_DEVICE_IOS_PREPARE_TIMEOUT_MS: "420000"
     steps:
       - name: Checkout
         uses: actions/checkout@de0fac2e4500dabe0009e67214ff5f5447ce83dd # v6.0.2
@@ -63,7 +64,7 @@ jobs:
       - name: Prepare iOS runner
         run: |
           pnpm clean:daemon
-          node --experimental-strip-types src/bin.ts prepare ios-runner --platform ios --timeout 240000
+          node --experimental-strip-types src/bin.ts prepare ios-runner --platform ios --timeout "$AGENT_DEVICE_IOS_PREPARE_TIMEOUT_MS"
           pnpm clean:daemon
 
       - name: Run iOS command perf benchmark

.github/workflows/replays-nightly.yml

@@ -53,6 +53,7 @@ jobs:
       IOS_RUNTIME_VERSION: '26.2'
       AGENT_DEVICE_STATE_DIR: ${{ github.workspace }}/.tmp/agent-device-state
       AGENT_DEVICE_IOS_RUNNER_DERIVED_PATH: ${{ github.workspace }}/.tmp/ios-runner-derived
+      AGENT_DEVICE_IOS_PREPARE_TIMEOUT_MS: '420000'
     steps:
       - name: Checkout
         uses: actions/checkout@de0fac2e4500dabe0009e67214ff5f5447ce83dd # v6.0.2
@@ -80,7 +81,7 @@ jobs:
       - name: Prepare iOS runner
         run: |
           pnpm clean:daemon
-          node --experimental-strip-types src/bin.ts prepare ios-runner --platform ios --timeout 300000 --json
+          node --experimental-strip-types src/bin.ts prepare ios-runner --platform ios --timeout "$AGENT_DEVICE_IOS_PREPARE_TIMEOUT_MS" --json
           pnpm clean:daemon
 
       - name: Run iOS simulator replay suite

src/daemon/handlers/__tests__/session-replay-vars.test.ts

@@ -768,6 +768,48 @@ test('runReplayScriptFile reports Maestro runScript failures at the runScript st
   assert.equal(calls.length, 0);
 });
 
+test('runReplayScriptFile reports iOS Maestro openLink setup failures before assertions', async () => {
+  const { response, calls } = await runReplayFixture({
+    label: 'maestro-ios-openlink-prewarm-fail',
+    script: [
+      'appId: demo.app',
+      '---',
+      '- openLink: demo://screen',
+      '- assertVisible: Ready',
+      '',
+    ].join('\n'),
+    flags: { replayBackend: 'maestro', platform: 'ios' },
+    invoke: async (req) => {
+      if (req.command === 'open') {
+        return {
+          ok: false,
+          error: {
+            code: 'COMMAND_FAILED',
+            message: 'Developer mode is disabled for Apple development tools',
+            details: {
+              hint: 'Run `sudo DevToolsSecurity -enable`.',
+            },
+          },
+        };
+      }
+      return { ok: true, data: {} };
+    },
+  });
+
+  assert.equal(response.ok, false);
+  if (!response.ok) {
+    assert.match(response.error.message, /Replay failed at step 1/);
+    assert.match(response.error.message, /open "demo\.app" "demo:\/\/screen"/);
+    assert.match(response.error.message, /Developer mode is disabled/);
+    assert.match(String(response.error.details?.hint ?? ''), /DevToolsSecurity -enable/);
+  }
+  assert.deepEqual(
+    calls.map((call) => [call.command, call.positionals]),
+    [['open', ['demo.app', 'demo://screen']]],
+  );
+  assert.equal(calls[0]?.flags?.maestro?.prewarmRunnerBeforeOpen, true);
+});
+
 test('runReplayScriptFile explains empty Maestro runScript JSON bodies', async () => {
   const { response, calls } = await runReplayFixture({
     label: 'maestro-runscript-empty-json',

src/daemon/handlers/__tests__/session.test.ts

@@ -2287,6 +2287,56 @@ test('open iOS Maestro app link waits for runner prewarm before launching app',
   });
 });
 
+test('open iOS Maestro app link reports blocking runner prewarm failures before launching app', async () => {
+  const sessionStore = makeSessionStore();
+  const sessionName = 'ios-maestro-open-link-prewarm-failed';
+  sessionStore.set(sessionName, {
+    ...makeSession(sessionName, {
+      platform: 'ios',
+      id: 'ios-device-1',
+      name: 'iPhone Device',
+      kind: 'device',
+      booted: true,
+    }),
+    appBundleId: 'com.example.previous',
+    appName: 'Previous App',
+  });
+  mockPrewarmIosRunnerSession.mockRejectedValueOnce(
+    new AppError('COMMAND_FAILED', 'Developer mode is disabled for Apple development tools', {
+      hint: 'Run `sudo DevToolsSecurity -enable`.',
+    }),
+  );
+
+  await expect(
+    handleSessionCommands({
+      req: {
+        token: 't',
+        session: sessionName,
+        command: 'open',
+        positionals: ['com.example.app', 'rne://screen-layout'],
+        flags: {
+          maestro: { prewarmRunnerBeforeOpen: true },
+        },
+      },
+      sessionName,
+      logPath: path.join(os.tmpdir(), 'daemon.log'),
+      sessionStore,
+      invoke: noopInvoke,
+    }),
+  ).rejects.toMatchObject({
+    code: 'COMMAND_FAILED',
+    message: 'Developer mode is disabled for Apple development tools',
+    details: {
+      hint: expect.stringContaining('DevToolsSecurity -enable'),
+    },
+  });
+  expect(mockDispatch).not.toHaveBeenCalled();
+  expect(mockPrewarmIosRunnerSession).toHaveBeenCalledWith(
+    expect.objectContaining({ platform: 'ios', id: 'ios-device-1' }),
+    expect.objectContaining({ propagateError: true }),
+  );
+});
+
 test('open iOS URL without app bundle id skips runner prewarm', async () => {
   const sessionStore = makeSessionStore();
   const sessionName = 'ios-device-session';

src/daemon/handlers/session-open.ts

@@ -198,7 +198,10 @@ async function completeOpenCommand(params: {
     timing.runnerPrewarmKind = 'session';
     timing.runnerPrewarmScheduled = true;
     if (shouldPrewarmRunnerBeforeOpen) {
-      runnerPrewarm = prewarmIosRunnerSession(device, runnerPrewarmOptions);
+      runnerPrewarm = prewarmIosRunnerSession(device, {
+        ...runnerPrewarmOptions,
+        propagateError: true,
+      });
       const runnerPrewarmStartedAtMs = Date.now();
       await runnerPrewarm;
       timing.runnerPrewarmWaited = true;

src/platforms/ios/__tests__/runner-command-retry.test.ts

@@ -196,6 +196,25 @@ test('prewarmIosRunnerSession proves cached runner health with uptime', async ()
   assert.equal(mockExecuteRunnerCommandWithSession.mock.calls[0]?.[4], 45_000);
 });
 
+test('prewarmIosRunnerSession can propagate setup failures for blocking callers', async () => {
+  const failure = new AppError('COMMAND_FAILED', 'Developer mode is disabled');
+  mockEnsureRunnerSession.mockRejectedValueOnce(failure);
+  const prewarm = prewarmIosRunnerSession(IOS_SIMULATOR, { propagateError: true });
+
+  assert.ok(prewarm);
+  await assert.rejects(prewarm, (error: unknown) => error === failure);
+
+  assert.deepEqual(mockEmitDiagnostic.mock.calls[0]?.[0], {
+    level: 'warn',
+    phase: 'ios_runner_session_prewarm_failed',
+    data: {
+      deviceId: IOS_SIMULATOR.id,
+      error: 'Developer mode is disabled',
+    },
+  });
+  assert.equal(mockEnsureRunnerSession.mock.calls[0]?.[1]?.propagateError, undefined);
+});
+
 test('prepareIosRunner does not force a rebuild when the relaunched fresh session still cannot connect', async () => {
   const missArtifact = makeRunnerArtifact({
     xctestrunPath: '/tmp/miss.xctestrun',

src/platforms/ios/__tests__/runner-session.test.ts

@@ -4,7 +4,7 @@ import fs from 'node:fs';
 import os from 'node:os';
 import path from 'node:path';
 import { beforeEach, test, vi } from 'vitest';
-import { IOS_SIMULATOR } from '../../../__tests__/test-utils/index.ts';
+import { IOS_DEVICE, IOS_SIMULATOR } from '../../../__tests__/test-utils/index.ts';
 import { AppError } from '../../../utils/errors.ts';
 import { flushDiagnosticsToSessionFile, withDiagnosticsScope } from '../../../utils/diagnostics.ts';
 import type { RunnerSession } from '../runner-session-types.ts';
@@ -612,18 +612,9 @@ test('runner session starts xcodebuild through provider seams and reuses an aliv
   await stopRunnerSession(session);
 });
 
-test('runner session fails early when Apple developer mode is disabled', async () => {
-  const device = { ...IOS_SIMULATOR, id: 'runner-session-devtools-disabled-sim' };
-  mockRunAppleToolCommand.mockImplementation(async (cmd, args) => {
-    if (cmd === 'DevToolsSecurity' && args[0] === '-status') {
-      return {
-        exitCode: 0,
-        stdout: 'Developer mode is currently disabled.\n',
-        stderr: '',
-      };
-    }
-    return { exitCode: 0, stdout: '', stderr: '' };
-  });
+test('runner session fails early for physical iOS devices when Apple developer mode is disabled', async () => {
+  const device = { ...IOS_DEVICE, id: 'runner-session-devtools-disabled-device' };
+  mockDevToolsSecurityDisabled();
 
   await assert.rejects(
     () => ensureRunnerSession(device, {}),
@@ -640,6 +631,18 @@ test('runner session fails early when Apple developer mode is disabled', async (
   assert.equal(mockRunCmdBackground.mock.calls.length, 0);
 });
 
+test('runner session does not require Apple developer mode for iOS simulators', async () => {
+  const device = { ...IOS_SIMULATOR, id: 'runner-session-devtools-disabled-sim' };
+  mockDevToolsSecurityDisabled();
+
+  const session = await ensureRunnerSession(device, {});
+
+  assert.equal(session.deviceId, device.id);
+  assert.equal(mockEnsureXctestrunArtifact.mock.calls.length, 1);
+  assert.equal(mockRunCmdBackground.mock.calls.length, 1);
+  assert.equal(mockRunAppleToolCommand.mock.calls.some(isDevToolsSecurityStatusCall), false);
+});
+
 test('runner session startup kills legacy ownerless xcodebuild before launching a new runner', async () => {
   const device = { ...IOS_SIMULATOR, id: 'runner-session-startup-stale-sim' };
 
@@ -884,6 +887,24 @@ function isXcodebuildPkillCall(call: unknown[]): boolean {
   return call[0] === 'pkill' && Array.isArray(args) && args.includes('-f');
 }
 
+function isDevToolsSecurityStatusCall(call: unknown[]): boolean {
+  const args = call[1];
+  return call[0] === 'DevToolsSecurity' && Array.isArray(args) && args[0] === '-status';
+}
+
+function mockDevToolsSecurityDisabled(): void {
+  mockRunAppleToolCommand.mockImplementation(async (cmd, args) => {
+    if (cmd === 'DevToolsSecurity' && args[0] === '-status') {
+      return {
+        exitCode: 0,
+        stdout: 'Developer mode is currently disabled.\n',
+        stderr: '',
+      };
+    }
+    return { exitCode: 0, stdout: '', stderr: '' };
+  });
+}
+
 function isSimctlTerminateCall(call: unknown[]): boolean {
   const args = call[0];
   return Array.isArray(args) && args.includes('simctl') && args.includes('terminate');

src/platforms/ios/runner-client.ts

@@ -59,14 +59,19 @@ export async function runIosRunnerCommand(
   return provider.runCommand(device, runnerCommand, options);
 }
 
+type PrewarmIosRunnerSessionOptions = RunnerSessionOptions & {
+  propagateError?: boolean;
+};
+
 export function prewarmIosRunnerSession(
   device: DeviceInfo,
-  options: RunnerSessionOptions = {},
+  options: PrewarmIosRunnerSessionOptions = {},
 ): Promise<void> | undefined {
   if (device.platform !== 'ios') {
     return undefined;
   }
-  const provider = resolveAppleRunnerRuntime(device, options);
+  const { propagateError = false, ...runnerOptions } = options;
+  const provider = resolveAppleRunnerRuntime(device, runnerOptions);
   if (!provider.prewarm) {
     emitDiagnostic({
       level: 'debug',
@@ -76,7 +81,7 @@ export function prewarmIosRunnerSession(
     return undefined;
   }
   const prewarm = provider
-    .prewarm(device, options)
+    .prewarm(device, runnerOptions)
     .then(() => {})
     .catch((error: unknown) => {
       emitDiagnostic({
@@ -87,6 +92,9 @@ export function prewarmIosRunnerSession(
           error: error instanceof Error ? error.message : String(error),
         },
       });
+      if (propagateError) {
+        throw error;
+      }
     });
   void prewarm;
   return prewarm;

src/platforms/ios/runner-session.ts

@@ -464,7 +464,7 @@ async function ensureBooted(device: DeviceInfo): Promise<void> {
 }
 
 async function verifyDeveloperModeForIosRunner(device: DeviceInfo): Promise<void> {
-  if (device.platform !== 'ios') return;
+  if (device.platform !== 'ios' || device.kind !== 'device') return;
   const result = await runAppleToolCommand('DevToolsSecurity', ['-status'], {
     allowFailure: true,
     timeoutMs: 2_000,