Fix version mismatch causing infinite worker restart loop (#567)

* Initial plan

* Fix version mismatch - update plugin/package.json and rebuild

Co-authored-by: thedotmack <683968+thedotmack@users.noreply.github.com>

* Add version consistency test suite

Co-authored-by: thedotmack <683968+thedotmack@users.noreply.github.com>

* Add documentation for version mismatch fix

Co-authored-by: thedotmack <683968+thedotmack@users.noreply.github.com>

---------

Co-authored-by: copilot-swe-agent[bot] <198982749+Copilot@users.noreply.github.com>
Co-authored-by: thedotmack <683968+thedotmack@users.noreply.github.com>

docs/VERSION_FIX.md

@@ -0,0 +1,79 @@
+# Version Consistency Fix (Issue #XXX)
+
+## Problem
+Version mismatch between plugin and worker caused infinite restart loop:
+- Plugin version: 9.0.0 (from plugin/.claude-plugin/plugin.json)
+- Worker binary version: 8.5.9 (hardcoded in bundled worker-service.cjs)
+
+This triggered the auto-restart mechanism on every hook call, which killed the SDK generator before it could complete the Claude API call to generate observations. Result: 0 observations were ever saved to the database despite hooks firing successfully.
+
+## Root Cause
+The `plugin/package.json` file had version `8.5.10` instead of `9.0.0`. When the project was last built, the build script correctly injected the version from root `package.json` into the bundled worker service. However, the `plugin/package.json` was manually created/edited and fell out of sync.
+
+At runtime:
+1. Worker service reads version from `~/.claude/plugins/marketplaces/thedotmack/package.json` → gets `8.5.10`
+2. Running worker returns built-in version via `/api/version` → returns `8.5.9` (from old build)
+3. Version check in `worker-service.ts` start command detects mismatch
+4. Auto-restart triggered on every hook call
+5. Observations never saved
+
+## Solution
+1. Updated `plugin/package.json` from version `8.5.10` to `9.0.0`
+2. Rebuilt all hooks and worker service to inject correct version (`9.0.0`) into bundled artifacts
+3. Added comprehensive test suite to prevent future version mismatches
+
+## Verification
+All versions now match:
+```
+Root package.json:       9.0.0 ✓
+plugin/package.json:     9.0.0 ✓
+plugin.json:             9.0.0 ✓
+marketplace.json:        9.0.0 ✓
+worker-service.cjs:      9.0.0 ✓
+```
+
+## Prevention
+To prevent this issue in the future:
+
+1. **Automated Build Process**: The `scripts/build-hooks.js` now regenerates `plugin/package.json` automatically with the correct version from root `package.json`
+
+2. **Version Consistency Tests**: Added `tests/infrastructure/version-consistency.test.ts` to verify all version sources match
+
+3. **Version Management Best Practices**:
+   - NEVER manually edit `plugin/package.json` - it's auto-generated during build
+   - Always update version in root `package.json` only
+   - Run `npm run build` after version changes
+   - The build script will sync the version to all necessary locations
+
+## Files Changed
+- `plugin/package.json` - Updated version from 8.5.10 to 9.0.0
+- `plugin/scripts/worker-service.cjs` - Rebuilt with version 9.0.0 injected
+- `plugin/scripts/mcp-server.cjs` - Rebuilt with version 9.0.0 injected
+- `plugin/scripts/*.js` (hooks) - Rebuilt with version 9.0.0 injected
+- `tests/infrastructure/version-consistency.test.ts` - New test suite
+
+## Testing
+Run the version consistency test:
+```bash
+npm run test:infra
+```
+
+Or manually verify:
+```bash
+node -e "
+const fs = require('fs');
+const rootPkg = JSON.parse(fs.readFileSync('package.json', 'utf-8'));
+const pluginPkg = JSON.parse(fs.readFileSync('plugin/package.json', 'utf-8'));
+const workerContent = fs.readFileSync('plugin/scripts/worker-service.cjs', 'utf-8');
+const workerMatch = workerContent.match(/Bre=\"([0-9.]+)\"/);
+console.log('Root:', rootPkg.version);
+console.log('Plugin:', pluginPkg.version);
+console.log('Worker:', workerMatch ? workerMatch[1] : 'NOT_FOUND');
+"
+```
+
+## Related Code Locations
+- **Version Injection**: `scripts/build-hooks.js` line 43-45, 105, 130, 155, 178
+- **Version Check**: `src/services/infrastructure/HealthMonitor.ts` line 133-143
+- **Auto-Restart Logic**: `src/services/worker-service.ts` line 627-645
+- **Runtime Version Read**: `src/shared/worker-utils.ts` line 73-76, 82-91