fix(ci,api): green main again — the four breaks that stopped every deploy for five days

[serge-ivo]

Main has been red since 50aecb9 (2026-09-01) and the API Worker has not deployed since 5876486. Production is running 5876486; everything after it — including d5701824's prompt-section tracing and 1e038c43's engine-invocation-mode change — is undeployed.

Four independent breaks. Main stays red until all four are gone, so they land together.

1. File-size ratchet (#302) — the one that made CI red

Three files grew without the pin move the guard asks for:

File	Pin	Actual	From
workers/api/src/routes/coding.ts	810 → 815	+5	1e038c43 (#731)
agents/coder/web/src/CodingTab.tsx	1478 → 1490	+12	1e038c43 (#731)
workers/api/src/agent-think.ts	1238 → 1251	+13	d5701824 (#732)

Reasons are written beside each pin, read off the diffs after the fact — which is the cost of raising a pin late, and is recorded as such on this file's own entry.

The ratchet runs ~11s in, before install, so CI never reached the test suite. That is why breaks 2–4 were only ever visible in the deploy workflows.

2. pages.ts never built before pnpm test

pnpm test could not collect workers/host/src/admin-api-proxy.test.ts: Cannot find module './pages.js'. pages.ts is build output (build.js inlines store/ into it) and is gitignored, so it does not exist in a fresh checkout — and neither ci.yml nor deploy-api.yml built it before running the suite.

Fixing only the ratchet would have moved main's redness here rather than clearing it.

Both workflows now build console → admin → host pages before pnpm test, the same chain and order as deploy-host.yml. In ci.yml this reuses the Build Console step that was already there as the job's last step, after the tests that needed it — moved, not duplicated. No docs build is added to deploy-api.yml: build.js guards a missing docs dir, so Zensical stays out of the API path.

3. Type-only import cycle

lib/usage.ts → lib/prompt-section-estimates.ts → lib/usage.ts, introduced by d5701824. Both edges are import type, so nothing failed at runtime — import-graph.test.ts is what catches it.

UsageKind now lives in usage-shape.ts, the leaf that already exists for exactly this and imports nothing; usage.ts re-exports it, so it stays the module you import a kind from. This is the connector-graph remedy that test documents (a leaf, not a deferred import) — EXPECTED_DEFERRED is untouched.

4. classifyEngineMetering had zero production callers

1e038c43 replaced its only call site with a direct expectedEngineInvocationMode check, re-opening the exact gap guard #556 was written to catch.

The invocation-mode refinement was right and is kept — it now lives inside the classifier as a third input, so one function still answers "can this reach the ledger" and the guard is satisfied by wiring rather than by a token call.

That detour also carried a second, quieter bug. It had to launder the engine name through asClient, which falls back to "claude" for anything outside its four-name list. So aider, opencode, goose, amp, crush and cursor-agent every one read as structured and recorded no absence at all — a day of unmeasured aider work looked identical to a day of measured Claude Code work on the Usage page. Going through the classifier (normalizePaneCommand + STRUCTURED_ENGINES) fixes that too.

Five new tests pin both behaviours: codex-launched-raw, the absent-launchCommand default (so no existing session reclassifies retroactively), and the six engines that were being swallowed.

Verification

• pages.ts moved aside reproduces break 2 exactly; the added build chain clears it.
• Full suite 606 files / 10845 tests passing (was 603 passed, 3 failed).
• Green: ratchet, biome, docs:drift, qa-config, test-isolation, e2e-projects.
• tsc clean: api, api tests (tsconfig.test.json), mcp, console.

Note on delivery

This repo's convention is commit-straight-to-main; this is a PR because it was explicitly requested for review before merge. Deploy API Worker will not run on merge unless workers/api/** changes — it does here, so merging should both green CI and ship the API backlog from 5876486 forward.

🤖 Generated with Claude Code