Capture daemon startup logs before window ready in e2e test (#10040)

The daemon health-check guard logs during main-process startup, which can
complete before the renderer window resolves. Moved stderr listening to the
launch options so early logs aren't missed. Also made the assertion regex
pattern-based instead of exact-string matching to tolerate benign log
rewording, and added a check that the replace path stayed off.

tests/e2e/daemon-slow-health-check-preservation.spec.ts

@@ -83,11 +83,13 @@ test('preserves a live daemon PTY when the daemon is too slow for the startup he
       }
     }, RESUME_DAEMON_AFTER_MS)
     try {
-      const secondLaunch = await session.launch()
-      secondApp = secondLaunch.app
-      secondApp.process().stderr?.on('data', (chunk: Buffer) => {
-        stderrLines.push(chunk.toString())
+      // Why: capture stderr from process start — the daemon guard logs its
+      // preservation decision during main-process startup, which can complete
+      // before firstWindow resolves, so a post-launch listener would miss it.
+      const secondLaunch = await session.launch({
+        onStderr: (chunk) => stderrLines.push(chunk)
       })
+      secondApp = secondLaunch.app
 
       await waitForSessionReady(secondLaunch.page)
       await expect
@@ -101,11 +103,15 @@ test('preserves a live daemon PTY when the daemon is too slow for the startup he
       await waitForPaneCount(secondLaunch.page, 1, 30_000)
       await waitForTerminalOutput(secondLaunch.page, marker, 20_000)
 
-      // The guard path must actually have run: the daemon failed the health
-      // check and was preserved because its live session was verified.
+      // The guard path must actually have run and chosen preserve over replace:
+      // the daemon failed the health check yet was kept because its live session
+      // was verified. Match the stable "preserve…daemon…health check" concepts
+      // (not the exact wording) so a benign log reword doesn't flake, and
+      // confirm the replace path stayed off.
       await expect
         .poll(() => stderrLines.join(''), { timeout: 10_000 })
-        .toContain('Preserving daemon that failed the health check')
+        .toMatch(/preserv\w*\s+daemon[^\n]*health check/i)
+      expect(stderrLines.join('')).not.toMatch(/\breplacing daemon\b/i)
       expect(readDaemonPid(session.userDataDir)).toBe(daemonPid)
       // Why: a killed daemon cold-restores scrollback from history, so the
       // marker text alone cannot distinguish a live session from a dead one.

tests/e2e/helpers/orca-restart.ts

@@ -34,9 +34,19 @@ type LaunchedOrca = {
   page: Page
 }
 
+type LaunchOptions = {
+  /**
+   * Called for each chunk the relaunched main process writes to stderr. The
+   * listener is attached before `firstWindow()` resolves so main-process
+   * startup logs (e.g. the daemon health-check guard) can't be emitted before
+   * the test starts capturing.
+   */
+  onStderr?: (chunk: string) => void
+}
+
 type RestartSession = {
   userDataDir: string
-  launch: () => Promise<LaunchedOrca>
+  launch: (options?: LaunchOptions) => Promise<LaunchedOrca>
   /** Gracefully close a launch, letting beforeunload flush session state. */
   close: (app: ElectronApplication) => Promise<void>
   /** Remove the shared userDataDir after the test is done. */
@@ -137,7 +147,7 @@ export function createRestartSession(
     `${JSON.stringify(getE2ECompletedOnboardingProfile(), null, 2)}\n`
   )
 
-  const launch = async (): Promise<LaunchedOrca> => {
+  const launch = async (options?: LaunchOptions): Promise<LaunchedOrca> => {
     runtimeWsPort ??= await reserveRestartRuntimeWsPort()
     const app = await electron.launch({
       args: getOrcaElectronLaunchArgs(mainPath, headful),
@@ -146,6 +156,12 @@ export function createRestartSession(
         ORCA_E2E_RUNTIME_WS_PORT: String(runtimeWsPort)
       }
     })
+    // Why: attach before firstWindow — the main-process daemon guard can emit
+    // its decision line during startup, before the renderer window is ready.
+    if (options?.onStderr) {
+      const onStderr = options.onStderr
+      app.process().stderr?.on('data', (chunk: Buffer) => onStderr(chunk.toString()))
+    }
     try {
       const resolvedHome = await app.evaluate(({ app }) => app.getPath('home'))
       assertElectronResolvedIsolatedHome(resolvedHome, homeIsolation)