fix(settings): clean up orphaned temp files and harden atomic writes

packages/web/server/lib/agent-memory/runtime.js

@@ -236,8 +236,13 @@ export const createAgentMemoryRuntime = (deps) => {
   const writeJsonAtomic = async (filePath, value) => {
     const temporaryPath = `${filePath}.tmp-${process.pid}-${Date.now()}-${Math.random().toString(16).slice(2)}`;
     await fsPromises.mkdir(path.dirname(filePath), { recursive: true });
-    await fsPromises.writeFile(temporaryPath, JSON.stringify(value, null, 2), 'utf8');
-    await fsPromises.rename(temporaryPath, filePath);
+    try {
+      await fsPromises.writeFile(temporaryPath, JSON.stringify(value, null, 2), 'utf8');
+      await fsPromises.rename(temporaryPath, filePath);
+    } catch (error) {
+      await fsPromises.rm(temporaryPath, { force: true }).catch(() => {});
+      throw error;
+    }
   };
 
   const withWriteLock = async (key, mutate) => {

packages/web/server/lib/opencode/settings-runtime.js

@@ -547,25 +547,41 @@ export const createSettingsRuntime = (deps) => {
     // briefly opens the target file. Preserve atomic rename everywhere it works,
     // but fall back to a direct replacement so settings persistence does not
     // get permanently wedged on Windows desktop installs.
-    await fsPromises.copyFile(tmp, target);
-    await fsPromises.rm(tmp, { force: true });
+    try {
+      await fsPromises.copyFile(tmp, target);
+    } finally {
+      await fsPromises.rm(tmp, { force: true }).catch(() => {});
+    }
+  };
+
+  const cleanupOrphanedSettingsTempFiles = async (directory) => {
+    try {
+      const entries = await fsPromises.readdir(directory, { withFileTypes: true });
+      const cleanupTasks = entries
+        .filter((entry) => entry.isFile() && entry.name.startsWith('settings.json.tmp-'))
+        .map((entry) => fsPromises.rm(path.join(directory, entry.name), { force: true }).catch(() => {}));
+      await Promise.all(cleanupTasks);
+    } catch {
+      // Best-effort cleanup: errors reading directory must not fail settings operations
+    }
   };
 
   const writeSettingsToDisk = async (settings) => {
+    const settingsDirectory = path.dirname(SETTINGS_FILE_PATH);
+    await fsPromises.mkdir(settingsDirectory, { recursive: true, mode: 0o700 });
+    if (process.platform !== 'win32') await fsPromises.chmod(settingsDirectory, 0o700);
+    // Atomic write: Electron main and ssh-manager read this file via plain
+    // readFile + JSON.parse and silently coerce parse errors to {}. A
+    // partial read during a non-atomic writeFile would make their next
+    // read-modify-write wipe the settings file.
+    const tmp = `${SETTINGS_FILE_PATH}.tmp-${process.pid}-${Date.now()}-${Math.random().toString(36).slice(2, 8)}`;
     try {
-      const settingsDirectory = path.dirname(SETTINGS_FILE_PATH);
-      await fsPromises.mkdir(settingsDirectory, { recursive: true, mode: 0o700 });
-      if (process.platform !== 'win32') await fsPromises.chmod(settingsDirectory, 0o700);
-      // Atomic write: Electron main and ssh-manager read this file via plain
-      // readFile + JSON.parse and silently coerce parse errors to {}. A
-      // partial read during a non-atomic writeFile would make their next
-      // read-modify-write wipe the settings file.
-      const tmp = `${SETTINGS_FILE_PATH}.tmp-${process.pid}-${Date.now()}-${Math.random().toString(36).slice(2, 8)}`;
       await fsPromises.writeFile(tmp, JSON.stringify(settings, null, 2), { encoding: 'utf8', mode: 0o600 });
       if (process.platform !== 'win32') await fsPromises.chmod(tmp, 0o600);
       await replaceFile(tmp, SETTINGS_FILE_PATH);
       if (process.platform !== 'win32') await fsPromises.chmod(SETTINGS_FILE_PATH, 0o600);
     } catch (error) {
+      await fsPromises.rm(tmp, { force: true }).catch(() => {});
       console.warn('Failed to write settings file:', error);
       throw error;
     }
@@ -854,7 +870,13 @@ export const createSettingsRuntime = (deps) => {
     return { settings: next, changed: true };
   };
 
+  let hasCleanedOrphanedTempFiles = false;
+
   const readSettingsFromDiskMigrated = async () => {
+    if (!hasCleanedOrphanedTempFiles) {
+      hasCleanedOrphanedTempFiles = true;
+      await cleanupOrphanedSettingsTempFiles(path.dirname(SETTINGS_FILE_PATH));
+    }
     const current = await readSettingsFromDisk();
     const migration1 = await migrateSettingsFromLegacyLastDirectory(current);
     const migration2 = await migrateSettingsFromLegacyThemePreferences(migration1.settings);

packages/web/server/lib/opencode/settings-runtime.test.js

@@ -151,4 +151,71 @@ describe('settings runtime', () => {
       await fsPromises.rm(tempRoot, { recursive: true, force: true });
     }
   });
+
+  it('cleans up orphaned settings.json.tmp files during startup migration', async () => {
+    const { runtime, settingsFilePath, tempRoot, cleanup } = await createRuntime();
+    try {
+      const settingsDir = path.dirname(settingsFilePath);
+      const orphan1 = path.join(settingsDir, 'settings.json.tmp-1234-11111-abc');
+      const orphan2 = path.join(settingsDir, 'settings.json.tmp-5678-22222-def');
+      const unrelated = path.join(settingsDir, 'other-file.json');
+
+      await fsPromises.writeFile(orphan1, '{"broken": true}', 'utf8');
+      await fsPromises.writeFile(orphan2, '{"broken": true}', 'utf8');
+      await fsPromises.writeFile(unrelated, '{"keep": true}', 'utf8');
+      await fsPromises.writeFile(settingsFilePath, '{"theme": "light"}', 'utf8');
+
+      await runtime.readSettingsFromDiskMigrated();
+
+      const files = await fsPromises.readdir(settingsDir);
+      expect(files).toContain('settings.json');
+      expect(files).toContain('other-file.json');
+      expect(files).not.toContain('settings.json.tmp-1234-11111-abc');
+      expect(files).not.toContain('settings.json.tmp-5678-22222-def');
+    } finally {
+      await cleanup();
+    }
+  });
+
+  it('removes temp file when writeSettingsToDisk encounters a write error', async () => {
+    const tempRoot = await fsPromises.mkdtemp(path.join(os.tmpdir(), 'oc-settings-runtime-'));
+    const settingsFilePath = path.join(tempRoot, 'settings.json');
+    let capturedTmp = null;
+    const wrappedFs = {
+      ...fsPromises,
+      rename: async (src, dst) => {
+        capturedTmp = src;
+        const error = new Error('unexpected disk failure');
+        error.code = 'EIO';
+        throw error;
+      },
+    };
+    const runtime = createSettingsRuntime({
+      fsPromises: wrappedFs,
+      path,
+      crypto,
+      SETTINGS_FILE_PATH: settingsFilePath,
+      sanitizeProjects: (projects) => Array.isArray(projects) ? projects : [],
+      sanitizeSettingsUpdate: (settings) => settings,
+      mergePersistedSettings: (_current, changes) => changes,
+      normalizeSettingsPaths: (settings) => ({ settings, changed: false }),
+      normalizeStringArray: (values) => Array.isArray(values) ? values.filter((value) => typeof value === 'string') : [],
+      formatSettingsResponse: (settings) => settings,
+      resolveDirectoryCandidate: (value) => value,
+      normalizeManagedRemoteTunnelHostname: (value) => value,
+      normalizeManagedRemoteTunnelPresets: (value) => value,
+      normalizeManagedRemoteTunnelPresetTokens: (value) => value,
+      syncManagedRemoteTunnelConfigWithPresets: async () => {},
+      upsertManagedRemoteTunnelToken: async () => {},
+    });
+
+    try {
+      await expect(runtime.writeSettingsToDisk({ theme: 'dark' })).rejects.toThrow('unexpected disk failure');
+      expect(capturedTmp).toBeTruthy();
+      const files = await fsPromises.readdir(tempRoot);
+      expect(files.some((f) => f.startsWith('settings.json.tmp-'))).toBe(false);
+    } finally {
+      await fsPromises.rm(tempRoot, { recursive: true, force: true });
+    }
+  });
 });

packages/web/server/lib/project-context/runtime.js

@@ -231,8 +231,13 @@ export const createProjectContextRuntime = (deps) => {
   const writeJsonAtomic = async (filePath, value) => {
     const temporaryPath = `${filePath}.tmp-${process.pid}-${Date.now()}-${Math.random().toString(16).slice(2)}`;
     await fsPromises.mkdir(path.dirname(filePath), { recursive: true });
-    await fsPromises.writeFile(temporaryPath, JSON.stringify(value, null, 2), 'utf8');
-    await fsPromises.rename(temporaryPath, filePath);
+    try {
+      await fsPromises.writeFile(temporaryPath, JSON.stringify(value, null, 2), 'utf8');
+      await fsPromises.rename(temporaryPath, filePath);
+    } catch (error) {
+      await fsPromises.rm(temporaryPath, { force: true }).catch(() => {});
+      throw error;
+    }
   };
 
   const withWriteLock = async (projectId, mutate) => {

packages/web/server/lib/projects/project-config.js

@@ -536,8 +536,13 @@ export const createProjectConfigRuntime = (deps) => {
     };
 
     await fsPromises.mkdir(parentDirectory, { recursive: true });
-    await fsPromises.writeFile(temporaryPath, JSON.stringify(merged, null, 2), 'utf8');
-    await fsPromises.rename(temporaryPath, filePath);
+    try {
+      await fsPromises.writeFile(temporaryPath, JSON.stringify(merged, null, 2), 'utf8');
+      await fsPromises.rename(temporaryPath, filePath);
+    } catch (error) {
+      await fsPromises.rm(temporaryPath, { force: true }).catch(() => {});
+      throw error;
+    }
   };
 
   const withProjectWriteLock = async (projectID, mutate) => {