Summary

Heavy-tier adversarial-review invocations crash with Input exceeds the maximum length of 1048576 characters. when buildAdversarialReviewPrompt interpolates a 256KB diff alongside the standard template. This is the follow-up scenario surfaced after PR #179 (256KB inline-diff cap) — that fix prevents ENOBUFS, but the assembled prompt can still exceed the Codex thread input cap on its own.

This PR adds a hard MAX_PROMPT_BYTES = 800 * 1024 byte cap on the assembled prompt (template + placeholders + content), plus a 3-step fallback chain that always stays under the cap.

Changes

plugins/codex/scripts/codex-companion.mjs

• buildAdversarialReviewPrompt is now exported and wraps its output in a 3-step fallback chain:
  1. Initial render — return verbatim if Buffer.byteLength(prompt, "utf8") <= MAX_PROMPT_BYTES.
  2. Lightweight fallback — swap guidance to "The repository context below is a lightweight summary. Inspect the target diff yourself..." (mirrors buildAdversarialCollectionGuidance({ includeDiff: false })) and rebuild REVIEW_INPUT from summary / changedFiles / fileCount (no diff body).
  3. Hard truncation — compute byte budget, walk back from UTF-8 continuation bytes ((buf[end] & 0xc0) === 0x80) to preserve valid sequences, and append \n\n[content truncated to fit prompt size limit]\n so the reviewer model can see truncation occurred.
• isDirectExecution() wraps main() so that importing the module from tests no longer runs the CLI as a side effect. Comparison uses fs.realpathSync.native() on both process.argv[1] and fileURLToPath(import.meta.url) so symlinked install paths (plugin cache, macOS /var vs /private/var) still match the entry. Lexical comparison remains as a fallback when realpath throws.

tests/codex-companion.test.mjs (new)

Five node:test cases covering:

Test plan

• node --check plugins/codex/scripts/codex-companion.mjs
• node --test tests/codex-companion.test.mjs → 5 / 5 pass
• node --test tests/*.test.mjs → 82 / 91 pass (9 pre-existing failures on main 807e03a: 5 in tests/runtime.test.mjs setup …, 3 in tests/commands.test.mjs status … / result …, 1 in tests/state.test.mjs resolveStateDir … — all reproduce on a clean upstream checkout and are unrelated to this PR)
• CLI smoke: node plugins/codex/scripts/codex-companion.mjs --help prints usage, confirming main() still runs through isDirectExecution()

Backward compatibility

• buildAdversarialReviewPrompt(context, focusText) keeps its existing 2-argument signature; the only existing caller (codex-companion.mjs line ~409, const prompt = buildAdversarialReviewPrompt(context, focusText)) is unchanged.
• collectReviewContext() return shape is untouched; the lightweight branch reads optional summary / changedFiles / fileCount fields it already populates.
• Existing inline / self-collect diff modes from PR fix: avoid embedding large adversarial review diffs #179 are preserved — the new cap only kicks in when the assembled prompt would exceed 800 KB.

Known follow-ups (out of scope for this PR)

These were surfaced during review and intentionally deferred:

1. stop-review-gate-hook.mjs has the same uncapped-prompt risk — last_assistant_message is interpolated into stop-review-gate.md and passed via process arguments without a byte cap. The fix shape is different (process argv vs inline string), so it warrants a separate PR.
2. Lightweight fallback file-name sanitization — when changedFiles is rendered into the lightweight summary, paths are joined with \n. Git rejects newlines in tracked paths so the practical injection surface is small, but defense-in-depth (JSON-encode or fence the list) is worth a follow-up.
3. Observability of fallback path — the function only returns the final prompt string, so operators can't see which fallback step ran. A future change could return { prompt, mode, originalBytes, finalBytes } and surface that in the job payload.

Notes on the constant

MAX_PROMPT_BYTES = 800 * 1024 (≈ 819 200 bytes) leaves a ~229 KB margin under the 1 048 576-character API cap. The API's limit is in code units while Buffer.byteLength(..., "utf8") counts bytes, so for ASCII the margin is the full 229 KB; for the (very rare) case of an all-multi-byte prompt the margin shrinks but never to zero with realistic content.

Closes cardene777/claude-config#1467