fix(gateway): harden service-mode stale process cleanup (#38463, thanks @spirittechie)

Co-authored-by: Jesse Paul <drzin69@gmail.com>

src/cli/gateway-cli/run.ts

@@ -17,6 +17,7 @@ import { setGatewayWsLogStyle } from "../../gateway/ws-logging.js";
 import { setVerbose } from "../../globals.js";
 import { GatewayLockError } from "../../infra/gateway-lock.js";
 import { formatPortDiagnostics, inspectPortUsage } from "../../infra/ports.js";
+import { cleanStaleGatewayProcessesSync } from "../../infra/restart-stale-pids.js";
 import { setConsoleSubsystemFilter, setConsoleTimestampPrefix } from "../../logging/console.js";
 import { createSubsystemLogger } from "../../logging/subsystem.js";
 import { defaultRuntime } from "../../runtime.js";
@@ -201,6 +202,14 @@ async function runGatewayCommand(opts: GatewayRunOpts) {
     defaultRuntime.exit(1);
     return;
   }
+  if (process.env.OPENCLAW_SERVICE_MARKER?.trim()) {
+    const stale = cleanStaleGatewayProcessesSync(port);
+    if (stale.length > 0) {
+      gatewayLog.info(
+        `service-mode: cleared ${stale.length} stale gateway pid(s) before bind on port ${port}`,
+      );
+    }
+  }
   if (opts.force) {
     try {
       const { killed, waitedMs, escalatedToSigkill } = await forceFreePortAndWait(port, {

src/daemon/systemd-unit.test.ts

@@ -19,6 +19,9 @@ describe("buildSystemdUnit", () => {
       environment: {},
     });
     expect(unit).toContain("KillMode=control-group");
+    expect(unit).toContain("TimeoutStopSec=30");
+    expect(unit).toContain("TimeoutStartSec=30");
+    expect(unit).toContain("SuccessExitStatus=0 143");
   });
 
   it("rejects environment values with line breaks", () => {

src/daemon/systemd-unit.ts

@@ -59,6 +59,9 @@ export function buildSystemdUnit({
     `ExecStart=${execStart}`,
     "Restart=always",
     "RestartSec=5",
+    "TimeoutStopSec=30",
+    "TimeoutStartSec=30",
+    "SuccessExitStatus=0 143",
     // Keep service children in the same lifecycle so restarts do not leave
     // orphan ACP/runtime workers behind.
     "KillMode=control-group",

src/infra/restart-stale-pids.ts

@@ -253,9 +253,12 @@ function waitForPortFreeSync(port: number): void {
  *
  * Called before service restart commands to prevent port conflicts.
  */
-export function cleanStaleGatewayProcessesSync(): number[] {
+export function cleanStaleGatewayProcessesSync(portOverride?: number): number[] {
   try {
-    const port = resolveGatewayPort(undefined, process.env);
+    const port =
+      typeof portOverride === "number" && Number.isFinite(portOverride) && portOverride > 0
+        ? Math.floor(portOverride)
+        : resolveGatewayPort(undefined, process.env);
     const stalePids = findGatewayPidsOnPortSync(port);
     if (stalePids.length === 0) {
       return [];

src/infra/restart.test.ts

@@ -95,6 +95,27 @@ describe.runIf(process.platform !== "win32")("cleanStaleGatewayProcessesSync", (
     expect(killSpy).toHaveBeenCalledWith(6002, "SIGKILL");
   });
 
+  it("uses explicit port override when provided", () => {
+    spawnSyncMock.mockReturnValue({
+      error: undefined,
+      status: 0,
+      stdout: ["p7001", "copenclaw"].join("\n"),
+    });
+    const killSpy = vi.spyOn(process, "kill").mockImplementation(() => true);
+
+    const killed = cleanStaleGatewayProcessesSync(19999);
+
+    expect(killed).toEqual([7001]);
+    expect(resolveGatewayPortMock).not.toHaveBeenCalled();
+    expect(spawnSyncMock).toHaveBeenCalledWith(
+      "/usr/sbin/lsof",
+      ["-nP", "-iTCP:19999", "-sTCP:LISTEN", "-Fpc"],
+      expect.objectContaining({ encoding: "utf8", timeout: 2000 }),
+    );
+    expect(killSpy).toHaveBeenCalledWith(7001, "SIGTERM");
+    expect(killSpy).toHaveBeenCalledWith(7001, "SIGKILL");
+  });
+
   it("returns empty when no stale listeners are found", () => {
     spawnSyncMock.mockReturnValue({
       error: undefined,