Fix auto-recovery for CRC-corrupt archives with correct file sizes

- Trust extractor CRC verdict over file size checks
- Re-queue incomplete downloads instead of just warning

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

src/main/download-manager.ts

@@ -4226,12 +4226,21 @@ export class DownloadManager extends EventEmitter {
       return 0;
     }
 
-    const corruptArchiveItems = archiveItems
-      .map((item) => ({ item, state: inspectPackageItemDiskState(pkg, item) }))
+    const inspectedArchiveItems = archiveItems
+      .map((item) => ({ item, state: inspectPackageItemDiskState(pkg, item) }));
+    const corruptArchiveItems = inspectedArchiveItems
       .filter(({ state }) => state.reason !== "ok");
+
     if (corruptArchiveItems.length === 0) {
-      logger.warn(`Auto-Recovery (${scope}): ${failure.archiveName} uebersprungen - kein lokaler Dateifehler nachweisbar`);
-      return 0;
+      // The extractor confirmed corruption (CRC error) but all files look
+      // correct by size.  This happens when content is corrupt despite having
+      // the right byte count (e.g. network corruption during download).
+      // Trust the extractor verdict and force re-download of ALL archive parts.
+      logger.warn(
+        `Auto-Recovery (${scope}): ${failure.archiveName} - Dateien korrekte Groesse aber Extractor meldet CRC-Fehler, ` +
+        `erzwinge Re-Download aller ${archiveItems.length} Parts`
+      );
+      corruptArchiveItems.push(...inspectedArchiveItems);
     }
 
     const queuedAt = nowMs();
@@ -7814,7 +7823,21 @@ export class DownloadManager extends EventEmitter {
           item.updatedAt = nowMs();
           this.recordRunOutcome(item.id, "completed");
         } else if (stat.size > 0) {
-          logger.warn(`Item-Recovery: ${item.fileName} übersprungen – Datei zu klein (${humanSize(stat.size)}, erwartet mind. ${humanSize(minSize)})`);
+          // File exists but is clearly incomplete — delete and re-queue for download.
+          logger.warn(`Item-Recovery: ${item.fileName} unvollstaendig (${humanSize(stat.size)}, erwartet mind. ${humanSize(minSize)}), loesche und re-queue`);
+          try {
+            fs.rmSync(item.targetPath, { force: true });
+          } catch { /* ignore */ }
+          this.releaseTargetPath(item.id);
+          this.dropItemContribution(item.id);
+          item.targetPath = "";
+          item.status = "queued";
+          item.attempts = 0;
+          item.downloadedBytes = 0;
+          item.progressPercent = 0;
+          item.speedBps = 0;
+          item.fullStatus = "Wartet (unvollständiger Download)";
+          item.updatedAt = nowMs();
         }
       } catch {
         // file doesn't exist, nothing to recover

tests/download-manager.test.ts

@@ -2042,7 +2042,7 @@ describe("download manager", () => {
     expect(session.packages[packageId]?.status).toBe("queued");
   });
 
-  it("does not requeue completed archive parts without local file evidence", () => {
+  it("requeues completed archive parts on CRC error even when file size matches", () => {
     const root = fs.mkdtempSync(path.join(os.tmpdir(), "rd-dm-"));
     tempDirs.push(root);
 
@@ -2121,13 +2121,18 @@ describe("download manager", () => {
       "hybrid"
     );
 
-    expect(changed).toBe(0);
+    // CRC error from extractor IS evidence of corruption — even when files
+    // have the right size, content may be corrupt.  Must force re-download.
+    expect(changed).toBe(2);
     for (const itemId of itemIds) {
       const item = session.items[itemId]!;
-      expect(item.status).toBe("completed");
-      expect(item.targetPath).toContain(".rar");
-      expect(item.downloadedBytes).toBe(archiveSize);
+      expect(item.status).toBe("queued");
+      expect(item.targetPath).toBe("");
+      expect(item.downloadedBytes).toBe(0);
+      expect(item.fullStatus).toContain("Auto-Recovery");
     }
+    expect(fs.existsSync(path.join(outputDir, archiveNames[0]!))).toBe(false);
+    expect(fs.existsSync(path.join(outputDir, archiveNames[1]!))).toBe(false);
   });
 
   it("does not treat rev files as ready archive parts during disk fallback", async () => {