fix(ci): give vitest no-output retries the full watchdog window

Shards that pin a short no-output timeout (agents-core stripes) die fast
on the known warm-cache stall, but a cold Vitest module cache makes the
same imports legitimately silent for minutes - the in-job retry then
re-dies at the short limit without running a single test (observed 4x
on agents-core-runner-cli-2 today). Raise the retry attempt's window to
the 300s watchdog floor while keeping the fast first kill.

scripts/test-projects.mjs

@@ -39,6 +39,7 @@ import {
   resolveChangedTargetArgs,
   shouldAcquireLocalHeavyCheckLock,
   shouldRetryVitestNoOutputTimeout,
+  withRetryNoOutputTimeout,
   writeVitestIncludeFile,
 } from "./test-projects.test-support.mjs";
 import { forceKillVitestProcessGroup } from "./vitest-process-group.mjs";
@@ -164,7 +165,7 @@ async function runLoggedVitestSpec(spec) {
   let result = await runVitestSpec(spec);
   if (result.noOutputTimedOut && !spec.watchMode && shouldRetryVitestNoOutputTimeout(spec.env)) {
     console.error(`[test] retrying ${spec.config} after no-output timeout`);
-    result = await runVitestSpec(spec);
+    result = await runVitestSpec(withRetryNoOutputTimeout(spec));
   }
   const durationMs = performance.now() - startedAt;
   if (result.noOutputTimedOut && result.signal) {

scripts/test-projects.test-support.d.mts

@@ -161,6 +161,9 @@ export function applyParallelVitestCachePaths<T extends { config: string; env: N
 ): Array<Omit<T, "env"> & { env: NodeJS.ProcessEnv }>;
 
 export function shouldRetryVitestNoOutputTimeout(env?: Record<string, string | undefined>): boolean;
+export function withRetryNoOutputTimeout<T extends { env?: Record<string, string | undefined> }>(
+  spec: T,
+): T;
 
 export function shouldAcquireLocalHeavyCheckLock(
   runSpecs: Array<Pick<VitestRunSpec, "config" | "includePatterns" | "watchMode">>,

scripts/test-projects.test-support.mjs

@@ -4578,6 +4578,27 @@ export function shouldRetryVitestNoOutputTimeout(env = process.env) {
   return !["0", "false", "no", "off"].includes(value ?? "");
 }
 
+// Shards may pin a short no-output window so the known warm-cache stall dies
+// fast (see AGENTS_CORE_RUNTIME_ENV in ci-node-test-plan.mjs). A cold Vitest
+// module cache makes those same imports legitimately silent for minutes, so
+// the retry attempt must get the full watchdog window or it re-dies at the
+// short limit and the job fails without ever running a test.
+const RETRY_NO_OUTPUT_TIMEOUT_FLOOR_MS = 300_000;
+
+export function withRetryNoOutputTimeout(spec) {
+  const current = Number(spec.env?.[VITEST_NO_OUTPUT_TIMEOUT_ENV_KEY]);
+  if (!Number.isFinite(current) || current <= 0 || current >= RETRY_NO_OUTPUT_TIMEOUT_FLOOR_MS) {
+    return spec;
+  }
+  return {
+    ...spec,
+    env: {
+      ...spec.env,
+      [VITEST_NO_OUTPUT_TIMEOUT_ENV_KEY]: String(RETRY_NO_OUTPUT_TIMEOUT_FLOOR_MS),
+    },
+  };
+}
+
 export function createVitestRunSpecs(args, params = {}) {
   const cwd = params.cwd ?? process.cwd();
   const baseEnv = params.baseEnv ?? process.env;

test/scripts/test-projects.test.ts

@@ -27,6 +27,7 @@ import {
   resolveChangedTargetArgs,
   resolveParallelFullSuiteConcurrency,
   shouldRetryVitestNoOutputTimeout,
+  withRetryNoOutputTimeout,
   writeVitestIncludeFile,
 } from "../../scripts/test-projects.test-support.mjs";
 import { captureReaddirSyncCallsDuring } from "../../src/test-utils/fs-scan-assertions.js";
@@ -5000,6 +5001,17 @@ describe("scripts/test-projects Vitest stall watchdog", () => {
   it("allows changed checks to disable automatic silent-run retries", () => {
     expect(shouldRetryVitestNoOutputTimeout({})).toBe(true);
     expect(shouldRetryVitestNoOutputTimeout({ CI: "true" })).toBe(false);
+  });
+
+  it("raises short shard no-output timeouts for the retry attempt", () => {
+    const spec = { env: { OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS: "60000" } };
+    expect(withRetryNoOutputTimeout(spec).env.OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS).toBe("300000");
+    const generous = { env: { OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS: "600000" } };
+    expect(withRetryNoOutputTimeout(generous)).toBe(generous);
+    const disabled = { env: { OPENCLAW_VITEST_NO_OUTPUT_TIMEOUT_MS: "0" } };
+    expect(withRetryNoOutputTimeout(disabled)).toBe(disabled);
+    const unset = { env: {} };
+    expect(withRetryNoOutputTimeout(unset)).toBe(unset);
     expect(shouldRetryVitestNoOutputTimeout({ GITHUB_ACTIONS: "true" })).toBe(false);
     expect(shouldRetryVitestNoOutputTimeout({ OPENCLAW_VITEST_NO_OUTPUT_RETRY: "1" })).toBe(true);
     expect(shouldRetryVitestNoOutputTimeout({ OPENCLAW_VITEST_NO_OUTPUT_RETRY: "0" })).toBe(false);