fix(build): replace manifest placeholder when SSR output is minified (#17874)

Rolldown's minifier rewrites string literals as template literals (backticks),
but the regex matching the `@@ASTRO_MANIFEST_REPLACE@@` placeholder only
accepted single and double quotes. Add backtick to the character class in
the manifest and server islands replacement regexes.

Fixes #17843

Co-authored-by: factory[bot] <factory[bot]@users.noreply.github.com>

Author: astro-factory[bot]

.changeset/beige-times-dream.md

@@ -0,0 +1,5 @@
+---
+'astro': patch
+---
+
+Fixes SSR manifest placeholder not being replaced when the server build is minified, which caused a runtime `Invalid URL` crash at server boot

packages/astro/src/core/build/plugins/plugin-manifest.ts

@@ -62,7 +62,8 @@ import { sessionConfigToManifest } from '../../session/utils.js';
  */
 
 export const MANIFEST_REPLACE = '@@ASTRO_MANIFEST_REPLACE@@';
-const replaceExp = new RegExp(`['"]${MANIFEST_REPLACE}['"]`, 'g');
+// Backtick included: Rolldown's minifier may rewrite string literals as template literals.
+const replaceExp = new RegExp(`['"\`]${MANIFEST_REPLACE}['"\`]`, 'g');
 
 /**
  * Post-build hook that injects the computed manifest into bundled chunks.

packages/astro/src/core/server-islands/vite-plugin-server-islands.ts

@@ -11,8 +11,9 @@ const RESOLVED_SERVER_ISLAND_MANIFEST = '\0' + SERVER_ISLAND_MANIFEST;
 const serverIslandPlaceholderMap = "'$$server-islands-map$$'";
 const serverIslandPlaceholderNameMap = "'$$server-islands-name-map$$'";
 export const SERVER_ISLAND_MAP_MARKER = '$$server-islands-map$$';
-const serverIslandMapReplaceExp = /['"]\$\$server-islands-map\$\$['"]/g;
-const serverIslandNameMapReplaceExp = /['"]\$\$server-islands-name-map\$\$['"]/g;
+// Backtick included: Rolldown's minifier may rewrite string literals as template literals.
+const serverIslandMapReplaceExp = /['"`]\$\$server-islands-map\$\$['"`]/g;
+const serverIslandNameMapReplaceExp = /['"`]\$\$server-islands-name-map\$\$['"`]/g;
 
 export function vitePluginServerIslands({
 	settings,

packages/astro/test/units/build/plugin-manifest.test.ts

@@ -0,0 +1,127 @@
+import assert from 'node:assert/strict';
+import { promises as fs } from 'node:fs';
+import path from 'node:path';
+import { describe, it } from 'node:test';
+import { fileURLToPath } from 'node:url';
+import type { Plugin } from 'vite';
+import { AstroBuilder } from '../../../dist/core/build/index.js';
+import { MANIFEST_REPLACE } from '../../../dist/core/build/plugins/plugin-manifest.js';
+import { parseRoute } from '../../../dist/core/routing/parse-route.js';
+import { createBasicSettings, defaultLogger } from '../test-utils.ts';
+import { virtualAstroModules } from './test-helpers.ts';
+
+async function readFilesRecursive(dir: string): Promise<string[]> {
+	const entries = await fs.readdir(dir, { withFileTypes: true });
+	const files = await Promise.all(
+		entries.map(async (entry) => {
+			const fullPath = path.join(dir, entry.name);
+			if (entry.isDirectory()) {
+				return readFilesRecursive(fullPath);
+			}
+			return [fullPath];
+		}),
+	);
+	return files.flat();
+}
+
+/**
+ * Vite plugin that enables minification for the SSR environment.
+ * This simulates what an integration would do via `astro:build:setup`.
+ */
+function enableSsrMinification(): Plugin {
+	return {
+		name: 'test-enable-ssr-minification',
+		configEnvironment(environmentName, config) {
+			if (environmentName === 'ssr') {
+				config.build ??= {};
+				config.build.minify = true;
+			}
+		},
+	};
+}
+
+describe('Build: Manifest injection', () => {
+	it('replaces manifest placeholder when server build is minified', async () => {
+		const root = new URL('./_temp-fixtures/', import.meta.url);
+
+		const settings = await createBasicSettings({
+			root: fileURLToPath(root),
+			output: 'server',
+			adapter: {
+				name: 'test-adapter',
+				hooks: {
+					'astro:config:done': ({ setAdapter }) => {
+						setAdapter({
+							name: 'test-adapter',
+							serverEntrypoint: 'astro/app',
+							exports: ['manifest', 'createApp'],
+							supportedAstroFeatures: {
+								serverOutput: 'stable',
+							},
+							adapterFeatures: {
+								buildOutput: 'server',
+							},
+						});
+					},
+				},
+			},
+			vite: {
+				plugins: [
+					virtualAstroModules(root, {
+						'src/pages/index.astro': [
+							'---',
+							'---',
+							'<html>',
+							'<head><title>Test</title></head>',
+							'<body><h1>Hello</h1></body>',
+							'</html>',
+						].join('\n'),
+					}),
+					enableSsrMinification(),
+				],
+			},
+		});
+
+		const routesList = {
+			routes: [
+				parseRoute('index.astro', settings, {
+					component: 'src/pages/index.astro',
+					prerender: false,
+				}),
+			],
+		};
+
+		process.env.ASTRO_KEY = 'eKBaVEuI7YjfanEXHuJe/pwZKKt3LkAHeMxvTU7aR0M=';
+
+		try {
+			const builder = new AstroBuilder(settings, {
+				logger: defaultLogger,
+				mode: 'production',
+				runtimeMode: 'production',
+				routesList,
+				sync: false,
+			});
+			await builder.run();
+		} finally {
+			delete process.env.ASTRO_KEY;
+		}
+
+		const serverOutputDir = fileURLToPath(settings.config.build.server);
+		const outputFiles = await readFilesRecursive(serverOutputDir);
+
+		// Find all server output files and verify none contain the unsubstituted placeholder
+		let foundManifestChunk = false;
+		for (const file of outputFiles) {
+			if (!file.endsWith('.mjs') && !file.endsWith('.js')) continue;
+			const content = await fs.readFile(file, 'utf-8');
+			if (content.includes('deserializeManifest') || content.includes('_deserializeManifest')) {
+				foundManifestChunk = true;
+				assert.ok(
+					!content.includes(MANIFEST_REPLACE),
+					`Manifest placeholder should be replaced in minified output but was found in ${path.basename(file)}`,
+				);
+			}
+		}
+		assert.ok(foundManifestChunk, 'Should find at least one chunk containing deserializeManifest');
+	});
+});