fix(plugins): guard provider discovery credential metadata

src/plugins/provider-discovery.runtime.test.ts

@@ -170,6 +170,19 @@ function createManifestPluginWithoutDiscovery(params: {
   };
 }
 
+function createPoisonedCredentialMetadataPlugin(params: {
+  id: string;
+  poison: "setup" | "providerAuthEnvVars";
+}): PluginManifestRecord {
+  const plugin = createManifestPluginWithoutDiscovery({ id: params.id });
+  return Object.defineProperty(plugin, params.poison, {
+    configurable: true,
+    get() {
+      throw new Error(`provider discovery ${params.poison} metadata exploded`);
+    },
+  });
+}
+
 function createProvider(params: { id: string; mode: "static" | "catalog" }): ProviderPlugin {
   const hook = {
     run: async () => ({
@@ -548,6 +561,45 @@ describe("resolvePluginDiscoveryProvidersRuntime", () => {
     expect(params.onlyPluginIds).toEqual(["kilocode"]);
   });
 
+  it("skips unreadable credential metadata while selecting full-load fallbacks", () => {
+    const codexEntryProvider = createProvider({ id: "codex", mode: "catalog" });
+    const fullProviders = [createProvider({ id: "kilocode", mode: "catalog" })];
+    mocks.resolveDiscoveredProviderPluginIds.mockReturnValue([
+      "codex",
+      "broken-setup",
+      "broken-auth-vars",
+      "kilocode",
+    ]);
+    mocks.loadPluginMetadataSnapshot.mockReturnValue({
+      index: { plugins: [] },
+      manifestRegistry: {
+        plugins: [
+          createManifestPlugin("codex"),
+          createPoisonedCredentialMetadataPlugin({ id: "broken-setup", poison: "setup" }),
+          createPoisonedCredentialMetadataPlugin({
+            id: "broken-auth-vars",
+            poison: "providerAuthEnvVars",
+          }),
+          createManifestPluginWithoutDiscovery({
+            id: "kilocode",
+            setupProviders: [{ id: "kilocode", envVars: ["KILOCODE_API_KEY"] }],
+          }),
+        ],
+        diagnostics: [],
+      },
+    });
+    mocks.loadSource.mockReturnValue(codexEntryProvider);
+    mocks.resolvePluginProviders.mockReturnValue(fullProviders);
+
+    expect(
+      resolvePluginDiscoveryProvidersRuntime({
+        env: { KILOCODE_API_KEY: "sk-test" } as NodeJS.ProcessEnv,
+      }),
+    ).toEqual([{ ...codexEntryProvider, pluginId: "codex" }, ...fullProviders]);
+    expect(mocks.resolvePluginProviders).toHaveBeenCalledTimes(1);
+    expect(requireResolvePluginProvidersParams().onlyPluginIds).toEqual(["kilocode"]);
+  });
+
   it("enables bundled provider Vitest compat when falling back from discovery entries", () => {
     const fullProviders = [createProvider({ id: "deepseek", mode: "catalog" })];
     mocks.resolveDiscoveredProviderPluginIds.mockReturnValue([]);

src/plugins/provider-discovery.runtime.ts

@@ -1,10 +1,10 @@
 import path from "node:path";
 import type { NormalizedModelCatalogRow } from "@openclaw/model-catalog-core/model-catalog-types";
 import { normalizeProviderId } from "@openclaw/model-catalog-core/provider-id";
+import { sortUniqueStrings } from "../../packages/normalization-core/src/string-normalization.js";
 import type { ModelDefinitionConfig, ModelProviderConfig } from "../config/types.models.js";
 import type { OpenClawConfig } from "../config/types.openclaw.js";
 import { planManifestModelCatalogRows } from "../model-catalog/manifest-planner.js";
-import { sortUniqueStrings } from "../../packages/normalization-core/src/string-normalization.js";
 import { loadManifestMetadataSnapshot } from "./manifest-contract-eligibility.js";
 import type { PluginManifestRecord } from "./manifest-registry.js";
 import { clearNativeRequireJavaScriptModuleCache } from "./native-module-require.js";
@@ -123,14 +123,18 @@ function hasProviderAuthEnvCredential(
   plugin: PluginManifestRecord,
   env: NodeJS.ProcessEnv,
 ): boolean {
-  const envVars = [
-    ...(plugin.setup?.providers ?? []).flatMap((provider) => provider.envVars ?? []),
-    ...Object.values(plugin.providerAuthEnvVars ?? {}).flat(),
-  ];
-  return envVars.some((name) => {
-    const value = env[name]?.trim();
-    return value !== undefined && value !== "";
-  });
+  try {
+    const envVars = [
+      ...(plugin.setup?.providers ?? []).flatMap((provider) => provider.envVars ?? []),
+      ...Object.values(plugin.providerAuthEnvVars ?? {}).flat(),
+    ];
+    return envVars.some((name) => {
+      const value = env[name]?.trim();
+      return value !== undefined && value !== "";
+    });
+  } catch {
+    return false;
+  }
 }
 
 function modelDefinitionCostFromManifestRow(