From ff5667a582293e11d7f5a78b3db99aa7809259eb Mon Sep 17 00:00:00 2001
From: Vincent Koc <vincentkoc@ieee.org>
Date: Wed, 3 Jun 2026 15:39:31 +0200
Subject: [PATCH] fix(installer): fail on onboarding exit code

---
 CHANGELOG.md                     |  1 +
 scripts/install.ps1              |  5 +++-
 test/scripts/install-ps1.test.ts | 48 ++++++++++++++++++++++++++++++++
 3 files changed, 53 insertions(+), 1 deletion(-)

diff --git a/CHANGELOG.md b/CHANGELOG.md
index 5c59f2c557a7..bba162b1211f 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -58,6 +58,7 @@ Docs: https://docs.openclaw.ai
 - Release/CI/E2E: fail the kitchen-sink RPC walk when command RSS sampling captures no process samples.
 - Release/CI/E2E: force-stop memory/fd repro gateway children that survive listener cleanup.
 - Release/CI/E2E: remove fallback ClawHub skill-install home directories when proof runs fail.
+- Installers: fail the PowerShell installer when interactive onboarding exits non-zero.
 - Scripts/UI: stop descendant processes from wrapped non-interactive commands when `run-with-env` receives shutdown signals.
 - Release/CI/E2E: write multi-node update Docker artifacts to unique per-run directories by default so parallel runs cannot overwrite evidence.
 - Release/CI/E2E: write package Telegram Docker artifacts to unique per-run directories by default so parallel live/RTT runs cannot overwrite evidence.
diff --git a/scripts/install.ps1 b/scripts/install.ps1
index f8484fe7d944..6fec0c6c9459 100644
--- a/scripts/install.ps1
+++ b/scripts/install.ps1
@@ -655,7 +655,10 @@ function Invoke-InteractiveOpenClawCommand {
         throw "openclaw command not found on PATH."
     }
 
-    $null = Start-Process -FilePath $commandPath -ArgumentList $Arguments -NoNewWindow -Wait -PassThru
+    $process = Start-Process -FilePath $commandPath -ArgumentList $Arguments -NoNewWindow -Wait -PassThru
+    if ($process.ExitCode -ne 0) {
+        throw "openclaw $($Arguments -join ' ') failed with exit code $($process.ExitCode)."
+    }
 }
 
 function Resolve-CommandPath {
diff --git a/test/scripts/install-ps1.test.ts b/test/scripts/install-ps1.test.ts
index cb3cdf1471c8..c67f81c89742 100644
--- a/test/scripts/install-ps1.test.ts
+++ b/test/scripts/install-ps1.test.ts
@@ -353,10 +353,58 @@ describe("install.ps1 failure handling", () => {
     expect(interactiveCommandBody).toContain("-NoNewWindow");
     expect(interactiveCommandBody).toContain("-Wait");
     expect(interactiveCommandBody).toContain("-PassThru");
+    expect(interactiveCommandBody).toContain("$process.ExitCode -ne 0");
+    expect(interactiveCommandBody).toContain("failed with exit code");
     expect(mainBody).toContain('Write-Host "Starting setup..." -ForegroundColor Cyan');
     expect(mainBody).toContain("Invoke-InteractiveOpenClawCommand onboard");
   });
 
+  runIfPowerShell("fails install when interactive onboarding exits non-zero", () => {
+    const tempDir = harness.createTempDir("openclaw-install-ps1-");
+    const scriptPath = join(tempDir, "install.ps1");
+    const scriptWithoutEntryPoint = source.replace(ENTRYPOINT_RE, "");
+    writeFileSync(
+      scriptPath,
+      [
+        scriptWithoutEntryPoint,
+        "",
+        "function Write-Banner { }",
+        "function Ensure-ExecutionPolicy { return $true }",
+        "function Check-Node { return $true }",
+        "function Check-ExistingOpenClaw { return $false }",
+        "function Get-NpmCommandPath { return 'npm.cmd' }",
+        "function Install-OpenClaw { return $true }",
+        "function Ensure-OpenClawOnPath { return $true }",
+        "function Add-ToUserPath { param([string]$Path) }",
+        "function Get-OpenClawCommandPath { return 'cmd.exe' }",
+        "function Start-Process {",
+        "  param([string]$FilePath, [string[]]$ArgumentList, [switch]$NoNewWindow, [switch]$Wait, [switch]$PassThru)",
+        "  [pscustomobject]@{ ExitCode = 17 }",
+        "}",
+        "$InstallMethod = 'npm'",
+        "$NoOnboard = $false",
+        "",
+        ...ENTRYPOINT_LINES,
+        "",
+      ].join("\n"),
+    );
+    chmodSync(scriptPath, 0o755);
+
+    const result = runPowerShell([
+      "-NoLogo",
+      "-NoProfile",
+      "-ExecutionPolicy",
+      "Bypass",
+      "-File",
+      scriptPath,
+    ]);
+
+    expect(result.status).toBe(1);
+    expect(`${result.stdout}\n${result.stderr}`).toContain(
+      "openclaw onboard failed with exit code 17",
+    );
+  });
+
   runIfPowerShell("exits non-zero when run as a script file", () => {
     const tempDir = harness.createTempDir("openclaw-install-ps1-");
     const scriptPath = join(tempDir, "install.ps1");