PreInstall runner: capture real exit codes, surface MSI errors
Three observability fixes that made the VC++ MSI failures actually debuggable instead of showing "Exit code - FAILED" with an empty value for every install: 1. Switch from Start-Process -PassThru (without -Wait) to [System.Diagnostics.Process]::Start() with a ProcessStartInfo. PowerShell 5.1 has a known bug where Start-Process disposes the Process object's OS handle when control returns to the script, so $proc.ExitCode reads as $null even after WaitForExit() - which was causing every MSI install to be reported as failed regardless of the actual result. 2. Pass /L*v <log> to msiexec on every MSI install so we get a full verbose log per app at C:\Logs\PreInstall\msi-<safename>.log. 3. On install failure, scan the verbose log for *meaningful* lines (Note: 1: <code>, "return value 3", custom action errors, "Failed to", "Installation failed", common 2xxx error codes) instead of tailing the last 25 lines, which is rollback/cleanup noise. This surfaces the actual root-cause line directly in the runner log so you don't have to dig through C:\Logs to diagnose. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
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cproudlock
@@ -184,22 +184,39 @@ foreach ($app in $config.Applications) {
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Write-PreInstallLog " InstallArgs: $($app.InstallArgs)"
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}
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# Per-app verbose msiexec log path - written by /L*v on MSI installs and tailed
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# into the runner log on failure so we don't need to dig through C:\Logs manually.
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$safeName = $app.Name -replace '[^a-zA-Z0-9]','_'
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$msiLog = Join-Path $logDir "msi-$safeName.log"
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if (Test-Path $msiLog) { Remove-Item $msiLog -Force -ErrorAction SilentlyContinue }
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try {
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# Start without -Wait so we can poll. UDC_Setup.exe in particular hangs forever
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# after install (it spawns UDC.exe and hides its main window without exiting),
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# so we can't rely on the process exiting on its own.
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# We use [System.Diagnostics.Process]::Start() directly instead of Start-Process
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# because PowerShell 5.1's Start-Process -PassThru has a bug where the returned
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# Process object's OS handle is disposed when control returns to the script,
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# causing ExitCode to always read as $null even after WaitForExit() succeeds.
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# Calling Process.Start() directly returns a Process object with a live handle
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# that exposes ExitCode correctly. We poll HasExited so UDC_Setup.exe (which
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# hangs forever after spawning a hidden WPF window) can be killed via the
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# detection-during-install path.
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$psi = New-Object System.Diagnostics.ProcessStartInfo
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$psi.UseShellExecute = $false
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$psi.CreateNoWindow = $true
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$psi.WindowStyle = [System.Diagnostics.ProcessWindowStyle]::Hidden
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if ($app.Type -eq "MSI") {
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$msiArgs = "/i `"$installerPath`""
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$psi.FileName = "msiexec.exe"
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$psi.Arguments = "/i `"$installerPath`""
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if ($app.InstallArgs) {
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$msiArgs += " " + $app.InstallArgs
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$psi.Arguments += " " + $app.InstallArgs
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}
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$proc = Start-Process -FilePath "msiexec.exe" -ArgumentList $msiArgs -PassThru -NoNewWindow
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$psi.Arguments += " /L*v `"$msiLog`""
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Write-PreInstallLog " msiexec verbose log: $msiLog"
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}
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elseif ($app.Type -eq "EXE") {
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$psi.FileName = $installerPath
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if ($app.InstallArgs) {
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$proc = Start-Process -FilePath $installerPath -ArgumentList $app.InstallArgs -PassThru -NoNewWindow
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} else {
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$proc = Start-Process -FilePath $installerPath -PassThru -NoNewWindow
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$psi.Arguments = $app.InstallArgs
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}
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}
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else {
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@@ -208,6 +225,8 @@ foreach ($app in $config.Applications) {
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continue
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}
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$proc = [System.Diagnostics.Process]::Start($psi)
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# Poll for completion: process exit OR detection success (whichever happens first)
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$timeoutSec = 600 # 10 min hard cap per app
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$pollInterval = 5
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@@ -256,16 +275,59 @@ foreach ($app in $config.Applications) {
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Write-PreInstallLog " SUCCESS (verified via detection during install)"
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$installed++
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}
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elseif ($proc.ExitCode -eq 0 -or $proc.ExitCode -eq 3010) {
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Write-PreInstallLog " Exit code $($proc.ExitCode) after $elapsed s - SUCCESS"
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if ($proc.ExitCode -eq 3010) {
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Write-PreInstallLog " (Reboot required for $($app.Name))"
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}
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$installed++
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}
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else {
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Write-PreInstallLog " Exit code $($proc.ExitCode) - FAILED" "ERROR"
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$failed++
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# Start-Process -PassThru returns a Process object whose ExitCode is null
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# until WaitForExit() is called - even if HasExited is already true. Without
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# this, every install that goes through the exit-code branch gets reported
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# as "Exit code - FAILED" (empty) regardless of the real result.
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try { $proc.WaitForExit() } catch { }
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$exitCode = $proc.ExitCode
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if ($exitCode -eq 0 -or $exitCode -eq 3010) {
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Write-PreInstallLog " Exit code $exitCode after $elapsed s - SUCCESS"
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if ($exitCode -eq 3010) {
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Write-PreInstallLog " (Reboot required for $($app.Name))"
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}
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$installed++
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}
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else {
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Write-PreInstallLog " Exit code $exitCode - FAILED" "ERROR"
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# Surface the *meaningful* lines from the verbose msiexec log (not just
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# the tail, which is rollback/cleanup noise). The actual root-cause lines
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# are: MSI error notes (Note: 1: <code>), failed action returns (return
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# value 3), errors logged by custom actions, and any line containing the
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# word "Error". Grep these out so the runner log shows the smoking gun.
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if ($app.Type -eq "MSI" -and (Test-Path $msiLog)) {
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Write-PreInstallLog " --- meaningful lines from $msiLog ---"
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$patterns = @(
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'Note: 1: ',
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'return value 3',
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'Error \d+\.',
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'CustomAction .* returned actual error',
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'Failed to ',
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'Installation failed',
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'Calling custom action',
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'1: 2262', # Database not found
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'1: 2203', # Cannot open database
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'1: 2330' # Insufficient permissions
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)
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$regex = ($patterns -join '|')
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$matches = Select-String -Path $msiLog -Pattern $regex -ErrorAction SilentlyContinue |
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Select-Object -First 30
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if ($matches) {
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foreach ($m in $matches) {
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Write-PreInstallLog " $($m.Line.Trim())"
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}
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} else {
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Write-PreInstallLog " (no error patterns matched - falling back to last 25 lines)"
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Get-Content $msiLog -Tail 25 -ErrorAction SilentlyContinue | ForEach-Object {
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Write-PreInstallLog " $_"
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}
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}
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Write-PreInstallLog " --- end MSI log scan ---"
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}
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$failed++
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}
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}
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} catch {
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Write-PreInstallLog " Install threw: $_" "ERROR"
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