fix(core): perform spawn check on ripgrep before registration

Author: aniruddhaadak80

packages/core/src/config/config.test.ts

@@ -25,6 +25,7 @@ import { ExperimentFlags } from '../code_assist/experiments/flagNames.js';
 import { debugLogger } from '../utils/debugLogger.js';
 import { coreEvents } from '../utils/events.js';
 import { ApprovalMode } from '../policy/types.js';
+import { execFileSync } from 'node:child_process';
 import {
   HookType,
   HookEventName,
@@ -154,6 +155,14 @@ vi.mock('../tools/memoryTool', async (importOriginal) => {
 
 vi.mock('../core/contentGenerator.js');
 
+vi.mock('node:child_process', async (importOriginal) => {
+  const actual = await importOriginal<typeof import('node:child_process')>();
+  return {
+    ...actual,
+    execFileSync: vi.fn(),
+  };
+});
+
 vi.mock('../core/client.js', () => ({
   GeminiClient: vi.fn().mockImplementation(() => ({
     initialize: vi.fn().mockResolvedValue(undefined),
@@ -2377,6 +2386,33 @@ describe('setApprovalMode with folder trust', () => {
       expect(event.error).toBe(String(error));
     });
 
+    it('should register GrepTool as a fallback when the ripgrep binary execution check throws an error', async () => {
+      vi.mocked(resolveRipgrepPath).mockResolvedValue('/mock/rg');
+      const error = new Error('spawn EFTYPE');
+      vi.mocked(execFileSync).mockImplementation(() => {
+        throw error;
+      });
+      const config = new Config({ ...baseParams, useRipgrep: true });
+      await config.initialize();
+
+      const calls = vi.mocked(ToolRegistry.prototype.registerTool).mock.calls;
+      const wasRipGrepRegistered = calls.some(
+        (call) => call[0] instanceof vi.mocked(RipGrepTool),
+      );
+      const wasGrepRegistered = calls.some(
+        (call) => call[0] instanceof vi.mocked(GrepTool),
+      );
+
+      expect(wasRipGrepRegistered).toBe(false);
+      expect(wasGrepRegistered).toBe(true);
+      expect(logRipgrepFallback).toHaveBeenCalledWith(
+        config,
+        expect.any(RipgrepFallbackEvent),
+      );
+      const event = vi.mocked(logRipgrepFallback).mock.calls[0][1];
+      expect(event.error).toBe(String(error));
+    });
+
     it('should register GrepTool when useRipgrep is false', async () => {
       const config = new Config({ ...baseParams, useRipgrep: false });
       await config.initialize();

packages/core/src/config/config.ts

@@ -9,6 +9,7 @@ import * as path from 'node:path';
 import { SandboxPolicyManager } from '../policy/sandboxPolicyManager.js';
 import { inspect } from 'node:util';
 import process from 'node:process';
+import { execFileSync } from 'node:child_process';
 import { z } from 'zod';
 import type { ConversationRecord } from '../services/chatRecordingService.js';
 import type {
@@ -2192,7 +2193,20 @@ export class Config implements McpContext, AgentLoopContext {
    * Checks if ripgrep is available.
    */
   async canUseRipgrep(): Promise<boolean> {
-    return (await this.getRipgrepPath()) !== null;
+    const rgPath = await this.getRipgrepPath();
+    if (rgPath === null) {
+      return false;
+    }
+    try {
+      execFileSync(rgPath, ['--version'], { stdio: 'ignore', timeout: 1000 });
+      return true;
+    } catch (error: unknown) {
+      debugLogger.warn(
+        `Ripgrep binary execution check failed at "${rgPath}":`,
+        error,
+      );
+      throw error;
+    }
   }
 
   /**