Fix Z.AI credential resolution and improve 401 auth diagnostics

src/daemon/clientFactory.test.ts

@@ -185,6 +185,26 @@ describe('createClientFromConfig', () => {
     }
   });
 
+  it('creates OpenAIClient for zhipuai using ZAI_API_KEY env var without use_oauth', async () => {
+    const prev = process.env.ZAI_API_KEY;
+    process.env.ZAI_API_KEY = 'zai-api-key';
+
+    try {
+      const { createClientFromConfig } = await loadFactory();
+      const client = createClientFromConfig({
+        provider: 'zhipuai',
+        model: 'glm-4.7',
+      });
+      expect(client.constructor.name).toBe('OpenAIClient');
+    } finally {
+      if (prev === undefined) {
+        delete process.env.ZAI_API_KEY;
+      } else {
+        process.env.ZAI_API_KEY = prev;
+      }
+    }
+  });
+
   it('creates OpenAIClient for minimax provider', async () => {
     const prev = process.env.MINIMAX_API_KEY;
     process.env.MINIMAX_API_KEY = 'test-key';

src/daemon/models.ts

@@ -33,17 +33,16 @@ function requireApiKey(cfg: ModelConfig, envVar: string): string {
   return key;
 }
 
-function resolveAuthCredential(cfg: ModelConfig, apiKeyEnvVar: string, authTokenEnvVar?: string): string {
+function resolveZaiCredential(cfg: ModelConfig): string {
   const raw = cfg.api_key
     ?? cfg.auth_token
-    ?? process.env[apiKeyEnvVar]
-    ?? (authTokenEnvVar ? process.env[authTokenEnvVar] : undefined);
+    ?? getZaiApiKey();
 
   if (!raw) {
-    const envHint = authTokenEnvVar ? `${apiKeyEnvVar} or ${authTokenEnvVar}` : apiKeyEnvVar;
     throw new Error(
-      `Credential required for ${cfg.provider}. ` +
-      `Set ${envHint} environment variable or provide api_key/auth_token in config.`,
+      'Z.AI credential not configured. ' +
+      'Run `flynn zai-auth` or set ZAI_API_KEY / ZHIPUAI_API_KEY / ZHIPUAI_AUTH_TOKEN, ' +
+      'or provide api_key/auth_token in config.',
     );
   }
 
@@ -197,24 +196,9 @@ export function createClientFromConfig(cfg: ModelConfig): ModelClient {
         baseURL: cfg.endpoint ?? 'https://ai-gateway.vercel.sh/v1',
       });
     case 'zhipuai':
-      if (cfg.use_oauth) {
-        const apiKey = getZaiApiKey();
-        if (!apiKey) {
-          throw new Error(
-            'Z.AI credential not configured. ' +
-            'Run `flynn zai-auth` or set ZAI_API_KEY / ZHIPUAI_API_KEY / ZHIPUAI_AUTH_TOKEN.',
-          );
-        }
-        return new OpenAIClient({
-          model: cfg.model,
-          apiKey,
-          baseURL: cfg.endpoint ?? 'https://api.z.ai/api/paas/v4',
-        });
-      }
-
       return new OpenAIClient({
         model: cfg.model,
-        apiKey: resolveAuthCredential(cfg, 'ZHIPUAI_API_KEY', 'ZHIPUAI_AUTH_TOKEN'),
+        apiKey: resolveZaiCredential(cfg),
         baseURL: cfg.endpoint ?? 'https://api.z.ai/api/paas/v4',
       });
     case 'xai':

src/models/openai.test.ts

@@ -135,4 +135,21 @@ describe('OpenAIClient tool use', () => {
 
     expect(response.stopReason).toBe('max_tokens');
   });
+
+  it('rewrites Z.AI 401 errors with actionable auth guidance', async () => {
+    mockCreate.mockRejectedValueOnce({
+      status: 401,
+      message: '401 You have insufficient permissions for this operation. Missing scopes: model.request.',
+    });
+
+    const client = new OpenAIClient({
+      apiKey: 'zai-key',
+      model: 'glm-4.7',
+      baseURL: 'https://api.z.ai/api/paas/v4',
+    });
+
+    await expect(client.chat({
+      messages: [{ role: 'user', content: 'hello' }],
+    })).rejects.toThrow(/Z\.AI authentication failed \(401\)/);
+  });
 });

src/models/openai.ts

@@ -61,10 +61,12 @@ export class OpenAIClient implements ModelClient {
   private model: string;
   private defaultMaxTokens: number;
   private useOAuth: boolean;
+  private baseURL?: string;
 
   constructor(config: OpenAIClientConfig) {
     const timeoutMs = config.timeoutMs ?? 20_000;
     this.useOAuth = Boolean(config.useOAuth);
+    this.baseURL = config.baseURL;
 
     // OAuth mode uses a different backend (ChatGPT Codex) and a different API shape.
     // Only initialize the OpenAI SDK for API-key providers.
@@ -248,7 +250,30 @@ export class OpenAIClient implements ModelClient {
       (params as any).reasoning_effort = 'medium';
     }
 
-    const response = await this.client.chat.completions.create(params);
+    let response: OpenAI.ChatCompletion;
+    try {
+      response = await this.client.chat.completions.create(params);
+    } catch (error) {
+      const status = typeof (error as { status?: unknown })?.status === 'number'
+        ? (error as { status: number }).status
+        : undefined;
+      const message = error instanceof Error ? error.message : String(error);
+
+      const isZai = (this.baseURL ?? '').includes('api.z.ai');
+      const missingModelRequestScope = message.includes('Missing scopes: model.request');
+
+      if (isZai && status === 401) {
+        const hint = missingModelRequestScope
+          ? 'The key lacks `model.request` scope.'
+          : 'The API key is invalid, expired, or not allowed for this model/endpoint.';
+        throw new Error(
+          `Z.AI authentication failed (401). ${hint} ` +
+          'Run `flynn zai-auth` to update credentials, or set ZAI_API_KEY / ZHIPUAI_API_KEY / ZHIPUAI_AUTH_TOKEN.',
+        );
+      }
+
+      throw error;
+    }
 
     const choice = response.choices[0];
     const content = choice?.message?.content ?? '';