fix(host): enforce the full kdump crash reservation

core/archipelago/src/host_fixups.rs

@@ -237,24 +237,39 @@ exit 2
     }
 }
 
-/// Append `crashkernel=` to the installed GRUB cmdline and run update-grub.
+/// Set the installed GRUB cmdline to one fixed `crashkernel=` reservation and
+/// run update-grub. Debian's kdump-tools package installs a grub.d snippet that
+/// otherwise appends its own range-based reservation after ours; on amd64 that
+/// silently wins and reserves only 192M instead of the intended 256M.
 /// The reservation itself only exists after the next reboot — memory cannot
 /// be set aside at runtime — so the caller must log the reboot caveat.
-/// Returns true if the cmdline changed.
+/// Returns true if the generated cmdline changed.
 async fn ensure_crashkernel_cmdline() -> Result<bool> {
     let script = format!(
         r#"
 set -u
 GRUB=/etc/default/grub
+KDUMP_GRUB=/etc/default/grub.d/kdump-tools.cfg
 PARAM='{CRASHKERNEL_PARAM}'
 [ -f "$GRUB" ] || exit 3
+CHANGED=0
+# kdump-tools sources this after /etc/default/grub and unconditionally appends
+# crashkernel=512M-:192M. Neutralize that package default: Archipelago owns the
+# explicit fixed reservation in GRUB_CMDLINE_LINUX_DEFAULT below.
+if [ -f "$KDUMP_GRUB" ] && grep -qE '^[^#]*crashkernel=' "$KDUMP_GRUB"; then
+    printf '%s\n' '# Archipelago owns crashkernel sizing in /etc/default/grub.' > "$KDUMP_GRUB"
+    CHANGED=1
+fi
 LINE=$(grep -E '^GRUB_CMDLINE_LINUX_DEFAULT=' "$GRUB" | head -1)
 [ -n "$LINE" ] || exit 3
-case "$LINE" in
-    *"$PARAM"*) exit 0 ;;
-esac
-NEWLINE=$(printf '%s' "$LINE" | sed "s/\"$/ $PARAM\"/")
-sed -i "s|^GRUB_CMDLINE_LINUX_DEFAULT=.*|$NEWLINE|" "$GRUB"
+# Remove any prior value before appending ours, so repeated fixups can never
+# create conflicting parameters whose kernel precedence is easy to misread.
+NEWLINE=$(printf '%s' "$LINE" | sed -E "s/[[:space:]]+crashkernel=[^ \"']+//g; s/\"$/ $PARAM\"/")
+if [ "$NEWLINE" != "$LINE" ]; then
+    sed -i "s|^GRUB_CMDLINE_LINUX_DEFAULT=.*|$NEWLINE|" "$GRUB"
+    CHANGED=1
+fi
+[ "$CHANGED" -eq 1 ] || exit 0
 timeout 120 update-grub >/dev/null 2>&1 || true
 exit 2
 "#

image-recipe/_archived/build-auto-installer-iso.sh

@@ -3746,6 +3746,13 @@ if [ -d "$BOOT_MEDIA/archipelago/plymouth-theme" ]; then
     # Configure clean boot: splash, suppress kernel noise, hide cursor
     sed -i 's/GRUB_CMDLINE_LINUX_DEFAULT=".*"/GRUB_CMDLINE_LINUX_DEFAULT="quiet splash loglevel=0 rd.systemd.show_status=false vt.global_cursor_default=0 acpi=force crashkernel=256M"/' \
         /mnt/target/etc/default/grub 2>/dev/null || true
+    # kdump-tools ships a grub.d snippet that appends crashkernel=512M-:192M
+    # after this line. The later value silently wins on amd64, so neutralize
+    # the package default and keep Archipelago's explicit fixed reservation.
+    if [ -f /mnt/target/etc/default/grub.d/kdump-tools.cfg ]; then
+        printf '%s\n' '# Archipelago owns crashkernel sizing in /etc/default/grub.' \
+            > /mnt/target/etc/default/grub.d/kdump-tools.cfg
+    fi
     echo "   Installed Archipelago Plymouth theme on target"
 fi
 

tests/lifecycle/os-audit.sh

@@ -242,14 +242,21 @@ section_d() {
   else
     record FAIL "kdump-tools configured" "/etc/default/kdump-tools missing USE_KDUMP=1 — host fixup didn't land"
   fi
-  # D2. crashkernel reservation — memory is reserved at BOOT, so a node that
-  # took the OTA fixup but hasn't rebooted yet is WARN, not FAIL.
-  if grep -q 'crashkernel=' /proc/cmdline 2>/dev/null; then
-    record PASS "crashkernel reserved" "$(grep -oE 'crashkernel=[^ ]+' /proc/cmdline | head -1)"
-  elif grep -q 'crashkernel=' /etc/default/grub 2>/dev/null; then
-    record WARN "crashkernel reserved" "written to GRUB — applies on next reboot"
+  # D2. crashkernel reservation — grade the memory the kernel actually
+  # reserved, not merely the first matching cmdline token. Debian's
+  # kdump-tools.cfg used to append a second crashkernel= range after our 256M;
+  # the audit falsely passed while /sys reported only 192M reserved.
+  local crash_size expected_size=$((256 * 1024 * 1024))
+  crash_size=$(cat /sys/kernel/kexec_crash_size 2>/dev/null || echo 0)
+  [[ "$crash_size" =~ ^[0-9]+$ ]] || crash_size=0
+  if (( crash_size >= expected_size )); then
+    record PASS "crashkernel reserved" "$((crash_size / 1024 / 1024))MiB actually reserved"
+  elif (( crash_size > 0 )); then
+    record FAIL "crashkernel reserved" "$((crash_size / 1024 / 1024))MiB reserved; expected >=256MiB (conflicting cmdline?)"
+  elif grep -q 'crashkernel=256M' /etc/default/grub 2>/dev/null; then
+    record WARN "crashkernel reserved" "256M written to GRUB — applies on next reboot"
   else
-    record FAIL "crashkernel reserved" "absent from /proc/cmdline AND /etc/default/grub"
+    record FAIL "crashkernel reserved" "no reservation and crashkernel=256M absent from GRUB"
   fi
   # D3. hang/panic capture policy — runtime-settable, expected immediately
   if [[ "$(cat /proc/sys/kernel/hung_task_panic 2>/dev/null)" == "1" ]]; then