fix(template): make prepare-win robust without prior Deploy run

- WinRM MaxProcessesPerShell: apply 100 if below threshold before asserting
- DesktopHeap SharedSection: apply 4096 KB registry value if below threshold before asserting
- Replace cleanmgr (hangs in WinRM Session 0, no window station) with direct
  PowerShell cleanup for dumps, WER files and Recycle Bin; DISM already covers
  component store and WU cache
- vcpkg git clone/checkout: wrap with EAP=Continue to suppress PS5.1
  NativeCommandError on git stderr (gotcha #3 from AGENTS.md)
- template.py: filter CI_EXITCODE:N marker from displayed output
- ci-static-ip.ps1: switch from vmware-rpctool (removed in recent Tools) to
  vmtoolsd --cmd; use temp-file redirect to capture output from native cmd

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

src/ci_orchestrator/commands/template.py

@@ -292,6 +292,13 @@ def _parse_exit_marker(stdout: str) -> int:
     return 0
 
 
+def _strip_exit_marker(stdout: str) -> str:
+    """Remove ``CI_EXITCODE:N`` lines from output before display."""
+    return "\n".join(
+        line for line in stdout.splitlines() if not line.strip().startswith("CI_EXITCODE:")
+    )
+
+
 def _wait_winrm(transport: WinRmTransport, timeout: int) -> None:
     """Poll *transport*.is_ready() until True or *timeout* seconds elapse."""
     deadline = time.monotonic() + timeout
@@ -532,8 +539,9 @@ def template_prepare_win(
             try:
                 result = _run_with_heartbeat(transport, invoke, check=False)
                 exit_code = _parse_exit_marker(result.stdout)
-                if result.stdout.strip():
+                display = _strip_exit_marker(result.stdout).strip()
-                    click.echo(result.stdout.strip())
+                if display:
+                    click.echo(display)
                 if result.stderr.strip():
                     click.echo(result.stderr.strip(), err=True)
             except TransportError:
@@ -658,8 +666,9 @@ Register-ScheduledTask -TaskName 'CI-StaticIp' `
             )
             cleanup_result = _run_with_heartbeat(transport, cleanup_invoke, check=False)
             cleanup_ec = _parse_exit_marker(cleanup_result.stdout)
-            if cleanup_result.stdout.strip():
+            display = _strip_exit_marker(cleanup_result.stdout).strip()
-                click.echo(cleanup_result.stdout.strip())
+            if display:
+                click.echo(display)
             if cleanup_result.stderr.strip():
                 click.echo(cleanup_result.stderr.strip(), err=True)
             if cleanup_ec != 0:

template/Install-CIToolchain-WinBuild2022.ps1

@@ -239,43 +239,15 @@ function Assert-Hash {
 function Invoke-DiskCleanup {
     Write-Step "Cleaning up disk"
 
-    $cleanKey = 'HKLM:\SOFTWARE\Microsoft\Windows\CurrentVersion\Explorer\VolumeCaches'
+    # cleanmgr.exe requires an interactive window station — hangs in WinRM Session 0.
-    $sageset  = 1
+    # Replicate the relevant categories with direct PowerShell cleanup instead.
-    $cleanCategories = @(
+    Write-Host "Clearing memory dumps..."
-        'Active Setup Temp Folders',
+    Remove-Item 'C:\Windows\Minidump\*' -Force -Recurse -ErrorAction SilentlyContinue
-        'BranchCache',
+    Remove-Item 'C:\Windows\memory.dmp' -Force           -ErrorAction SilentlyContinue
-        'Downloaded Program Files',
+    Write-Host "Clearing Windows Error Reporting files..."
-        'Internet Cache Files',
+    Remove-Item 'C:\ProgramData\Microsoft\Windows\WER\*' -Force -Recurse -ErrorAction SilentlyContinue
-        'Memory Dump Files',
+    Write-Host "Clearing Recycle Bin..."
-        'Old ChkDsk Files',
+    Clear-RecycleBin -DriveLetter C -Force -ErrorAction SilentlyContinue
-        'Previous Installations',
-        'Recycle Bin',
-        'Service Pack Cleanup',
-        'Setup Log Files',
-        'System error memory dump files',
-        'System error minidump files',
-        'Temporary Files',
-        'Temporary Setup Files',
-        'Thumbnail Cache',
-        'Update Cleanup',
-        'Upgrade Discarded Files',
-        'Windows Defender',
-        'Windows Error Reporting Archive Files',
-        'Windows Error Reporting Files',
-        'Windows Error Reporting Queue Files',
-        'Windows Error Reporting Temp Files',
-        'Windows ESD installation files',
-        'Windows Upgrade Log Files'
-    )
-    foreach ($cat in $cleanCategories) {
-        $keyPath = "$cleanKey\$cat"
-        if (Test-Path $keyPath) {
-            Set-ItemProperty -Path $keyPath -Name "StateFlags$('{0:D4}' -f $sageset)" -Value 2 -Type DWord -Force -ErrorAction SilentlyContinue
-        }
-    }
-    Write-Host "Running cleanmgr /sagerun:$sageset (may take a few minutes)..."
-    $proc = Start-Process -FilePath 'cleanmgr.exe' -ArgumentList "/sagerun:$sageset" -Wait -PassThru
-    Write-Host "cleanmgr exited (code $($proc.ExitCode))."
 
     Write-Host "Stopping WU-adjacent services before cache clear..."
     foreach ($svc in 'wuauserv', 'UsoSvc', 'bits', 'dosvc', 'TrustedInstaller') {
@@ -437,9 +409,18 @@ Assert-Step 'WinRM' 'Shell MaxMemoryPerShellMB >= 2048' {
 Assert-Step 'WinRM' 'Plugin Microsoft.PowerShell MaxMemoryPerShellMB >= 2048' {
     [int](Get-Item 'WSMan:\localhost\Plugin\Microsoft.PowerShell\Quotas\MaxMemoryPerShellMB').Value -ge 2048
 }
+if ([int](Get-Item WSMan:\localhost\Shell\MaxProcessesPerShell -ErrorAction SilentlyContinue).Value -lt 100) {
+    Set-Item WSMan:\localhost\Shell\MaxProcessesPerShell 100 -Force
+}
 Assert-Step 'WinRM' 'MaxProcessesPerShell >= 100' {
     [int](Get-Item WSMan:\localhost\Shell\MaxProcessesPerShell).Value -ge 100
 }
+$_subsysKey = 'HKLM:\SYSTEM\CurrentControlSet\Control\Session Manager\SubSystems'
+$_subsysCur = (Get-ItemProperty $_subsysKey -Name Windows).Windows
+if (-not ($_subsysCur -match 'SharedSection=\d+,\d+,(\d+)') -or [int]$Matches[1] -lt 4096) {
+    $subsysNew = $_subsysCur -replace 'SharedSection=(\d+),(\d+),\d+', 'SharedSection=$1,$2,4096'
+    Set-ItemProperty $_subsysKey -Name Windows -Value $subsysNew
+}
 Assert-Step 'DesktopHeap' 'SharedSection non-interactive >= 4096 KB' {
     $w = (Get-ItemProperty -Path 'HKLM:\SYSTEM\CurrentControlSet\Control\Session Manager\SubSystems' -Name Windows).Windows
     if ($w -match 'SharedSection=\d+,\d+,(\d+)') { [int]$Matches[1] -ge 4096 } else { $false }
@@ -1587,11 +1568,15 @@ if (Test-Path $vcpkgExe) {
         $cloneArgs += '--depth'
         $cloneArgs += '1'
     }
+    $savedEap = $ErrorActionPreference; $ErrorActionPreference = 'Continue'
     & $gitBin.Source @cloneArgs 2>&1 | Write-Host
+    $ErrorActionPreference = $savedEap
     if ($LASTEXITCODE -ne 0) { throw "vcpkg git clone failed (exit $LASTEXITCODE)." }
     if ($VcpkgRef -ne '') {
         Write-Host "Checking out vcpkg ref: $VcpkgRef"
+        $savedEap = $ErrorActionPreference; $ErrorActionPreference = 'Continue'
         & $gitBin.Source -C $vcpkgDir checkout $VcpkgRef 2>&1 | Write-Host
+        $ErrorActionPreference = $savedEap
         if ($LASTEXITCODE -ne 0) { throw "vcpkg checkout '$VcpkgRef' failed (exit $LASTEXITCODE)." }
     }
     Write-Host "Bootstrapping vcpkg (-disableMetrics)..."

template/Install-CIToolchain-WinBuild2025.ps1

@@ -239,47 +239,17 @@ function Assert-Hash {
 function Invoke-DiskCleanup {
     Write-Step "Cleaning up disk"
 
-    # 1. Windows Disk Cleanup (cleanmgr) — run with /sagerun:1 using preset flags
+    # cleanmgr.exe requires an interactive window station — hangs in WinRM Session 0.
-    #    First register the flags via /sageset:1 in the registry (silent, no UI)
+    # Replicate the relevant categories with direct PowerShell cleanup instead.
-    $cleanKey = 'HKLM:\SOFTWARE\Microsoft\Windows\CurrentVersion\Explorer\VolumeCaches'
+    Write-Host "Clearing memory dumps..."
-    $sageset  = 1
+    Remove-Item 'C:\Windows\Minidump\*' -Force -Recurse -ErrorAction SilentlyContinue
-    $cleanCategories = @(
+    Remove-Item 'C:\Windows\memory.dmp' -Force           -ErrorAction SilentlyContinue
-        'Active Setup Temp Folders',
+    Write-Host "Clearing Windows Error Reporting files..."
-        'BranchCache',
+    Remove-Item 'C:\ProgramData\Microsoft\Windows\WER\*' -Force -Recurse -ErrorAction SilentlyContinue
-        'Downloaded Program Files',
+    Write-Host "Clearing Recycle Bin..."
-        'Internet Cache Files',
+    Clear-RecycleBin -DriveLetter C -Force -ErrorAction SilentlyContinue
-        'Memory Dump Files',
-        'Old ChkDsk Files',
-        'Previous Installations',
-        'Recycle Bin',
-        'Service Pack Cleanup',
-        'Setup Log Files',
-        'System error memory dump files',
-        'System error minidump files',
-        'Temporary Files',
-        'Temporary Setup Files',
-        'Thumbnail Cache',
-        'Update Cleanup',
-        'Upgrade Discarded Files',
-        'Windows Defender',
-        'Windows Error Reporting Archive Files',
-        'Windows Error Reporting Files',
-        'Windows Error Reporting Queue Files',
-        'Windows Error Reporting Temp Files',
-        'Windows ESD installation files',
-        'Windows Upgrade Log Files'
-    )
-    foreach ($cat in $cleanCategories) {
-        $keyPath = "$cleanKey\$cat"
-        if (Test-Path $keyPath) {
-            Set-ItemProperty -Path $keyPath -Name "StateFlags$('{0:D4}' -f $sageset)" -Value 2 -Type DWord -Force -ErrorAction SilentlyContinue
-        }
-    }
-    Write-Host "Running cleanmgr /sagerun:$sageset (may take a few minutes)..."
-    $proc = Start-Process -FilePath 'cleanmgr.exe' -ArgumentList "/sagerun:$sageset" -Wait -PassThru
-    Write-Host "cleanmgr exited (code $($proc.ExitCode))."
 
-    # 2. Clear Windows Update cache
+    # Clear Windows Update cache
     Write-Host "Stopping WU-adjacent services before cache clear..."
     foreach ($svc in 'wuauserv', 'UsoSvc', 'bits', 'dosvc', 'TrustedInstaller') {
         Stop-Service -Name $svc -Force -ErrorAction SilentlyContinue
@@ -451,9 +421,18 @@ Assert-Step 'WinRM' 'Shell MaxMemoryPerShellMB >= 2048' {
 Assert-Step 'WinRM' 'Plugin Microsoft.PowerShell MaxMemoryPerShellMB >= 2048' {
     [int](Get-Item 'WSMan:\localhost\Plugin\Microsoft.PowerShell\Quotas\MaxMemoryPerShellMB').Value -ge 2048
 }
+if ([int](Get-Item WSMan:\localhost\Shell\MaxProcessesPerShell -ErrorAction SilentlyContinue).Value -lt 100) {
+    Set-Item WSMan:\localhost\Shell\MaxProcessesPerShell 100 -Force
+}
 Assert-Step 'WinRM' 'MaxProcessesPerShell >= 100' {
     [int](Get-Item WSMan:\localhost\Shell\MaxProcessesPerShell).Value -ge 100
 }
+$_subsysKey = 'HKLM:\SYSTEM\CurrentControlSet\Control\Session Manager\SubSystems'
+$_subsysCur = (Get-ItemProperty $_subsysKey -Name Windows).Windows
+if (-not ($_subsysCur -match 'SharedSection=\d+,\d+,(\d+)') -or [int]$Matches[1] -lt 4096) {
+    $subsysNew = $_subsysCur -replace 'SharedSection=(\d+),(\d+),\d+', 'SharedSection=$1,$2,4096'
+    Set-ItemProperty $_subsysKey -Name Windows -Value $subsysNew
+}
 Assert-Step 'DesktopHeap' 'SharedSection non-interactive >= 4096 KB' {
     $w = (Get-ItemProperty -Path 'HKLM:\SYSTEM\CurrentControlSet\Control\Session Manager\SubSystems' -Name Windows).Windows
     if ($w -match 'SharedSection=\d+,\d+,(\d+)') { [int]$Matches[1] -ge 4096 } else { $false }
@@ -1601,11 +1580,15 @@ if (Test-Path $vcpkgExe) {
         $cloneArgs += '--depth'
         $cloneArgs += '1'
     }
+    $savedEap = $ErrorActionPreference; $ErrorActionPreference = 'Continue'
     & $gitBin.Source @cloneArgs 2>&1 | Write-Host
+    $ErrorActionPreference = $savedEap
     if ($LASTEXITCODE -ne 0) { throw "vcpkg git clone failed (exit $LASTEXITCODE)." }
     if ($VcpkgRef -ne '') {
         Write-Host "Checking out vcpkg ref: $VcpkgRef"
+        $savedEap = $ErrorActionPreference; $ErrorActionPreference = 'Continue'
         & $gitBin.Source -C $vcpkgDir checkout $VcpkgRef 2>&1 | Write-Host
+        $ErrorActionPreference = $savedEap
         if ($LASTEXITCODE -ne 0) { throw "vcpkg checkout '$VcpkgRef' failed (exit $LASTEXITCODE)." }
     }
     Write-Host "Bootstrapping vcpkg (-disableMetrics)..."

template/guest-setup/windows/ci-static-ip.ps1

@@ -31,16 +31,24 @@
 Set-StrictMode -Version Latest
 $ErrorActionPreference = 'Stop'
 
-$vmtoolsRpc = 'C:\Program Files\VMware\VMware Tools\vmware-rpctool.exe'
+# vmware-rpctool.exe was removed in recent VMware Tools versions; use vmtoolsd --cmd instead.
-if (-not (Test-Path $vmtoolsRpc -PathType Leaf)) { exit 0 }
+$vmtoolsd = 'C:\Program Files\VMware\VMware Tools\vmtoolsd.exe'
+if (-not (Test-Path $vmtoolsd -PathType Leaf)) { exit 0 }
 
 function Read-GuestInfo {
     param([string]$Key)
+    # vmtoolsd writes to a file handle but not to a PS pipeline — use cmd.exe redirection.
+    $tmp = [System.IO.Path]::GetTempFileName()
+    try {
         $savedEap = $ErrorActionPreference; $ErrorActionPreference = 'Continue'
-    $out = & $vmtoolsRpc "info-get guestinfo.$Key" 2>&1
+        cmd /c "`"$vmtoolsd`" --cmd `"info-get guestinfo.$Key`" > `"$tmp`" 2>&1"
         $ErrorActionPreference = $savedEap
-    if ($LASTEXITCODE -eq 0 -and $out -notmatch 'No value found|^$') {
+        $text = (Get-Content $tmp -ErrorAction SilentlyContinue | Out-String).Trim()
-        return ($out | Out-String).Trim()
+        if ($text -and $text -notmatch 'No value found|Error') {
+            return $text
+        }
+    } finally {
+        Remove-Item $tmp -ErrorAction SilentlyContinue
     }
     return ''
 }
@@ -75,22 +83,22 @@ if (-not $adapter) {
     exit 1
 }
 
-# Disable DHCP and remove any existing IPv4 addresses.
+# Disable DHCP and remove any existing IPv4 addresses and routes.
 $adapter | Set-NetIPInterface -Dhcp Disabled -ErrorAction SilentlyContinue
+Get-NetRoute -InterfaceAlias $adapter.Name -AddressFamily IPv4 -ErrorAction SilentlyContinue |
+    Remove-NetRoute -Confirm:$false -ErrorAction SilentlyContinue
 $adapter | Get-NetIPAddress -AddressFamily IPv4 -ErrorAction SilentlyContinue |
     Remove-NetIPAddress -Confirm:$false -ErrorAction SilentlyContinue
 
-# Apply static IP.
+# Apply static IP (no DefaultGateway here — add route separately to avoid conflicts).
-$ipParams = @{
+New-NetIPAddress -InterfaceAlias $adapter.Name -IPAddress $ip `
-    InterfaceAlias = $adapter.Name
+    -PrefixLength $prefix -ErrorAction Stop | Out-Null
-    IPAddress      = $ip
+
-    PrefixLength   = $prefix
+# Add default route if gateway supplied.
-    ErrorAction    = 'Stop'
-}
 if ($gateway -match '^\d{1,3}(\.\d{1,3}){3}$') {
-    $ipParams['DefaultGateway'] = $gateway
+    New-NetRoute -InterfaceAlias $adapter.Name -DestinationPrefix '0.0.0.0/0' `
+        -NextHop $gateway -ErrorAction SilentlyContinue | Out-Null
 }
-New-NetIPAddress @ipParams | Out-Null
 
 # Use the gateway as DNS (fallback: Google DNS).
 $dns = @()
@@ -101,7 +109,7 @@ Set-DnsClientServerAddress -InterfaceAlias $adapter.Name `
 
 # Report IP back via guestinfo.ci-ip so the host also has it.
 $savedEap = $ErrorActionPreference; $ErrorActionPreference = 'Continue'
-& $vmtoolsRpc "info-set guestinfo.ci-ip $ip" 2>&1 | Out-Null
+& $vmtoolsd --cmd "info-set guestinfo.ci-ip $ip" 2>&1 | Out-Null
 $ErrorActionPreference = $savedEap
 
 exit 0