feat(update): pre-flight gates + deeper healthcheck + auto-rollback

Phase 8 of v0.3. Tightens the update lifecycle on both ends.

Pre-flight (apply.go, before any download):
- Free-space check on the passive partition: image size + 10% headroom must
  be available. Uses statfs(2) via the new pkg/partition.FreeBytes /
  HasFreeSpaceFor helpers (tests cover happy path, tiny request, huge
  request, missing path). Catches corrupted-FS and shrunk-partition cases
  before we destroy the existing slot data.
- Node-block-label check: refuses if the local K8s node carries the
  updates.kubesolo.io/block=true label. New pkg/health.CheckNodeBlocked
  shells out to kubectl per the project's zero-deps stance. Silently bypassed
  when no kubeconfig is reachable (air-gap case). Skipped by --force.

Healthcheck (extended via new pkg/health/extended.go + preflight.go):
- CheckKubeSystemReady waits until every kube-system pod has held the Running
  phase for >= N seconds (default 30). Catches "started ok, will crash-loop"
  bugs that a single-shot phase check misses.
- CheckProbeURL fetches an operator-supplied URL; 200 = pass. Wired through
  update.conf as healthcheck_url= and cloud-init updates.healthcheck_url.
- CheckDiskWritable writes/fsyncs/reads a 1-KiB probe under /var/lib/kubesolo.
  Always runs in healthcheck so a wedged data partition fails fast.
- pkg/health.Status grows KubeSystemReady, ProbeURL, DiskWritable booleans.
  Optional checks default to true in RunAll() so they don't block when
  unconfigured. health_test.go updated to the new 6-field shape.

Auto-rollback (healthcheck.go):
- state.UpdateState gains HealthCheckFailures (consecutive post-Activated
  failures). Reset on a clean pass.
- --auto-rollback-after N (also auto_rollback_after= in update.conf) triggers
  env.ForceRollback() when the failure count reaches the threshold. State
  transitions to RolledBack with a descriptive LastError. The command still
  exits with the healthcheck error; the operator/init is expected to reboot.
- Only fires while Phase == Activated. Doesn't second-guess a long-stable
  system that happens to fail one healthcheck.

config / opts / cloud-init plumbing:
- update.conf gains healthcheck_url= and auto_rollback_after= keys.
- New CLI flags: --healthcheck-url, --auto-rollback-after, --kube-system-settle.
- cloud-init full-config.yaml documents the new updates: subfields.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

cloud-init/examples/full-config.yaml

@@ -72,3 +72,14 @@ updates:
   # Path to Ed25519 public key for signature verification. Omit to disable
   # signature verification (NOT recommended for production fleets).
   # pubkey: "/etc/kubesolo/update-pubkey.hex"
+
+  # Optional post-boot healthcheck probe URL. If set, healthcheck GETs it
+  # and treats anything other than HTTP 200 as a failure. Useful when your
+  # workload exposes its own readiness on a known endpoint.
+  # healthcheck_url: "http://localhost:8000/ready"
+
+  # Auto-rollback threshold: after N consecutive post-activation healthcheck
+  # failures, the agent triggers a rollback on its own. 0 disables the
+  # feature (the bootloader still does GRUB-counter-based rollback after
+  # 3 failed boots). Recommended: 3 for production fleets.
+  # auto_rollback_after: 3

update/cmd/apply.go

@@ -4,10 +4,12 @@ import (
 	"context"
 	"fmt"
 	"log/slog"
+	"os"
 	"runtime"
 	"time"
 
 	"github.com/portainer/kubesolo-os/update/pkg/config"
+	"github.com/portainer/kubesolo-os/update/pkg/health"
 	"github.com/portainer/kubesolo-os/update/pkg/image"
 	"github.com/portainer/kubesolo-os/update/pkg/oci"
 	"github.com/portainer/kubesolo-os/update/pkg/partition"
@@ -71,6 +73,19 @@ func Apply(args []string) error {
 			window.String())
 	}
 
+	// Node-block-label gate — workload authors can defer an update by
+	// labeling the node updates.kubesolo.io/block=true. Skipped with --force
+	// and silently bypassed when the K8s API isn't reachable (air-gap).
+	if !opts.Force {
+		blocked, berr := health.CheckNodeBlocked("")
+		if berr != nil {
+			slog.Warn("node-block check failed, allowing update", "error", berr)
+		} else if blocked {
+			return fmt.Errorf("node carries label %s=true; refusing update (pass --force to override)",
+				health.NodeBlockLabel)
+		}
+	}
+
 	st, err := state.Load(opts.StatePath)
 	if err != nil {
 		// Don't block the operation on a corrupt state file. Log + recover.
@@ -186,6 +201,30 @@ func Apply(args []string) error {
 	}
 	defer partition.Unmount(mountPoint)
 
+	// Free-space pre-write check: the passive partition must have at least
+	// (kernel + initramfs) + 10% headroom. Catches corrupted-FS reports and
+	// shrunk/wrong-size partitions before we destroy the existing slot data.
+	var imgSize int64
+	for _, p := range []string{staged.VmlinuzPath, staged.InitramfsPath} {
+		fi, ferr := os.Stat(p)
+		if ferr != nil {
+			_ = st.RecordError(opts.StatePath, fmt.Errorf("stat staged file %s: %w", p, ferr))
+			return fmt.Errorf("stat staged file %s: %w", p, ferr)
+		}
+		imgSize += fi.Size()
+	}
+	avail, ok, ferr := partition.HasFreeSpaceFor(mountPoint, imgSize, 10)
+	if ferr != nil {
+		_ = st.RecordError(opts.StatePath, fmt.Errorf("free-space check: %w", ferr))
+		return fmt.Errorf("free-space check: %w", ferr)
+	}
+	if !ok {
+		err := fmt.Errorf("insufficient space on %s: have %.1f MiB, need %.1f MiB (image + 10%% headroom)",
+			passiveSlot, float64(avail)/(1<<20), float64(imgSize)*1.1/(1<<20))
+		_ = st.RecordError(opts.StatePath, err)
+		return err
+	}
+
 	// Write image to passive partition
 	if err := partition.WriteSystemImage(mountPoint, staged.VmlinuzPath, staged.InitramfsPath, staged.Version); err != nil {
 		_ = st.RecordError(opts.StatePath, fmt.Errorf("writing system image: %w", err))

update/cmd/healthcheck.go

@@ -17,6 +17,11 @@ import (
 // State transition: Activated → Verifying → Success on pass, → Failed on fail.
 // If state isn't in Activated (e.g. manual run on a long-stable system), the
 // state file is left alone — healthcheck still does its job.
+//
+// When --auto-rollback-after N is set, consecutive post-Activated failures
+// are counted in state.HealthCheckFailures. On the Nth failure, the agent
+// calls Rollback() and the operator is expected to reboot (this command
+// does not reboot the host — that's policy left to systemd/init).
 func Healthcheck(args []string) error {
 	opts := parseOpts(args)
 	env := opts.NewBootEnv()
@@ -48,18 +53,44 @@ func Healthcheck(args []string) error {
 
 	timeout := time.Duration(opts.TimeoutSecs) * time.Second
 	checker := health.NewChecker("", "", timeout)
+	checker.ProbeURL = opts.HealthcheckURL
+	if opts.KubeSystemSettle > 0 {
+		checker.KubeSystemSettle = time.Duration(opts.KubeSystemSettle) * time.Second
+	}
+	// Probe the data partition every healthcheck so a wedged disk fails fast.
+	checker.DataDir = "/var/lib/kubesolo"
 
-	slog.Info("running post-boot health checks", "timeout", timeout)
+	slog.Info("running post-boot health checks",
+		"timeout", timeout,
+		"probe_url", checker.ProbeURL,
+		"kube_system_settle", checker.KubeSystemSettle)
 
 	status, err := checker.WaitForHealthy()
 	if err != nil {
 		fmt.Printf("Health check FAILED: %s\n", status.Message)
-		fmt.Printf("  containerd: %v\n", status.Containerd)
-		fmt.Printf("  apiserver:  %v\n", status.APIServer)
-		fmt.Printf("  node_ready: %v\n", status.NodeReady)
+		printStatusBreakdown(status)
 		fmt.Println("\nBoot NOT marked successful — system may roll back on next reboot")
+
 		if postActivation {
+			st.HealthCheckFailures++
 			_ = st.RecordError(opts.StatePath, fmt.Errorf("post-boot health check failed: %s", status.Message))
+
+			// Auto-rollback escalation. Only trigger when post-Activated;
+			// don't second-guess a healthy long-running system.
+			if opts.AutoRollbackAfter > 0 && st.HealthCheckFailures >= opts.AutoRollbackAfter {
+				slog.Warn("auto-rollback threshold reached",
+					"failures", st.HealthCheckFailures,
+					"threshold", opts.AutoRollbackAfter)
+				if rerr := env.ForceRollback(); rerr != nil {
+					slog.Error("auto-rollback failed", "error", rerr)
+					return err // return the original healthcheck error
+				}
+				if terr := st.Transition(opts.StatePath, state.PhaseRolledBack, "",
+					fmt.Sprintf("auto-rollback after %d healthcheck failures", st.HealthCheckFailures)); terr != nil {
+					slog.Warn("state transition failed", "phase", state.PhaseRolledBack, "error", terr)
+				}
+				fmt.Println("\nAuto-rollback triggered. Reboot to complete the rollback.")
+			}
 		}
 		return err
 	}
@@ -73,15 +104,32 @@ func Healthcheck(args []string) error {
 	}
 
 	if postActivation {
+		// Reset failure counter on a clean pass.
+		st.HealthCheckFailures = 0
 		if err := st.Transition(opts.StatePath, state.PhaseSuccess, "", ""); err != nil {
 			slog.Warn("state transition failed", "phase", state.PhaseSuccess, "error", err)
 		}
 	}
 
 	fmt.Println("Health check PASSED — boot marked successful")
-	fmt.Printf("  containerd: %v\n", status.Containerd)
-	fmt.Printf("  apiserver:  %v\n", status.APIServer)
-	fmt.Printf("  node_ready: %v\n", status.NodeReady)
+	printStatusBreakdown(status)
 
 	return nil
 }
+
+// printStatusBreakdown emits a human-readable per-check summary. Only emits
+// optional check lines when they actually ran.
+func printStatusBreakdown(s *health.Status) {
+	fmt.Printf("  containerd:        %v\n", s.Containerd)
+	fmt.Printf("  apiserver:         %v\n", s.APIServer)
+	fmt.Printf("  node_ready:        %v\n", s.NodeReady)
+	if !s.KubeSystemReady {
+		fmt.Printf("  kube-system pods:  %v\n", s.KubeSystemReady)
+	}
+	if !s.ProbeURL {
+		fmt.Printf("  probe URL:         %v\n", s.ProbeURL)
+	}
+	if !s.DiskWritable {
+		fmt.Printf("  disk writable:     %v\n", s.DiskWritable)
+	}
+}

update/cmd/opts.go

@@ -18,12 +18,15 @@ type opts struct {
 	PubKeyPath        string
 	BootEnvType       string // "grub" or "rpi"
 	BootEnvPath       string // path for RPi boot control dir
-	StatePath         string // location of state.json (default: state.DefaultPath)
-	ConfPath          string // location of update.conf (default: config.DefaultPath)
-	Channel           string // update channel ("stable" by default)
-	MaintenanceWindow string // "HH:MM-HH:MM" or empty for always-allow
-	Force             bool   // bypass maintenance window
-	JSON              bool   // status: emit JSON instead of human-readable
+	StatePath          string // location of state.json (default: state.DefaultPath)
+	ConfPath           string // location of update.conf (default: config.DefaultPath)
+	Channel            string // update channel ("stable" by default)
+	MaintenanceWindow  string // "HH:MM-HH:MM" or empty for always-allow
+	HealthcheckURL     string // optional GET probe for healthcheck
+	AutoRollbackAfter  int    // healthcheck: rollback after N consecutive failures (0=off)
+	KubeSystemSettle   int    // healthcheck: kube-system pods must be Running for N seconds (0=disabled)
+	Force              bool   // bypass maintenance window
+	JSON               bool   // status: emit JSON instead of human-readable
 }
 
 // NewBootEnv creates a BootEnv from the parsed options.
@@ -74,6 +77,12 @@ func parseOpts(args []string) opts {
 		if cfg.PubKey != "" {
 			o.PubKeyPath = cfg.PubKey
 		}
+		if cfg.HealthcheckURL != "" {
+			o.HealthcheckURL = cfg.HealthcheckURL
+		}
+		if cfg.AutoRollbackAfter > 0 {
+			o.AutoRollbackAfter = cfg.AutoRollbackAfter
+		}
 	} else if err != nil {
 		slog.Warn("could not load update.conf", "path", o.ConfPath, "error", err)
 	}
@@ -100,6 +109,43 @@ func parseOpts(args []string) opts {
 			}
 		case "--force":
 			o.Force = true
+		case "--healthcheck-url":
+			if i+1 < len(args) {
+				o.HealthcheckURL = args[i+1]
+				i++
+			}
+		case "--auto-rollback-after":
+			if i+1 < len(args) {
+				n := 0
+				for _, ch := range args[i+1] {
+					if ch >= '0' && ch <= '9' {
+						n = n*10 + int(ch-'0')
+					} else {
+						n = 0
+						break
+					}
+				}
+				if n > 0 {
+					o.AutoRollbackAfter = n
+				}
+				i++
+			}
+		case "--kube-system-settle":
+			if i+1 < len(args) {
+				n := 0
+				for _, ch := range args[i+1] {
+					if ch >= '0' && ch <= '9' {
+						n = n*10 + int(ch-'0')
+					} else {
+						n = 0
+						break
+					}
+				}
+				if n > 0 {
+					o.KubeSystemSettle = n
+				}
+				i++
+			}
 		case "--json":
 			o.JSON = true
 		case "--server":

update/main.go

@@ -90,6 +90,9 @@ Options:
   --grubenv PATH        Path to grubenv file (default: /boot/grub/grubenv)
   --timeout SECS        Health check timeout in seconds (default: 120)
   --pubkey PATH         Ed25519 public key for signature verification (optional)
+  --healthcheck-url URL Optional GET probe in healthcheck; 200 = pass
+  --auto-rollback-after N  healthcheck: rollback after N consecutive failures
+  --kube-system-settle N healthcheck: require kube-system pods Running ≥ N seconds
   --json                For 'status': emit JSON instead of human-readable output
 
 Examples:

update/pkg/config/config.go

@@ -35,6 +35,13 @@ type Config struct {
 	Channel           string
 	MaintenanceWindow string
 	PubKey            string
+	// HealthcheckURL is an optional URL the healthcheck command will GET;
+	// 200 = pass, anything else = fail.
+	HealthcheckURL string
+	// AutoRollbackAfter is the number of consecutive post-boot healthcheck
+	// failures after which the agent will call Rollback automatically.
+	// 0 = disabled (default).
+	AutoRollbackAfter int
 }
 
 // Load reads and parses update.conf. A missing file returns an empty Config
@@ -73,6 +80,21 @@ func Load(path string) (*Config, error) {
 			c.MaintenanceWindow = value
 		case "pubkey":
 			c.PubKey = value
+		case "healthcheck_url":
+			c.HealthcheckURL = value
+		case "auto_rollback_after":
+			// Parse a small integer. Non-numeric values are silently
+			// ignored (forward compat); zero disables the feature.
+			n := 0
+			for _, ch := range value {
+				if ch >= '0' && ch <= '9' {
+					n = n*10 + int(ch-'0')
+				} else {
+					n = 0
+					break
+				}
+			}
+			c.AutoRollbackAfter = n
 		}
 		// Unknown keys are silently ignored for forward compatibility.
 	}

update/pkg/health/extended.go

@@ -0,0 +1,125 @@
+package health
+
+import (
+	"context"
+	"fmt"
+	"net/http"
+	"os"
+	"os/exec"
+	"path/filepath"
+	"strings"
+	"time"
+)
+
+// kubeSystemSettleSeconds is how long all kube-system pods must hold a
+// Running phase before we consider the cluster genuinely up. Catches the
+// "pod just started, will crash-loop in 5s" case.
+const kubeSystemSettleSeconds = 30
+
+// CheckKubeSystemReady verifies that every pod in the kube-system namespace
+// is in Running phase and has been Running for at least settle. Returns
+// (ready, error). settle defaults to 30s when zero.
+func (c *Checker) CheckKubeSystemReady(settle time.Duration) bool {
+	if settle == 0 {
+		settle = kubeSystemSettleSeconds * time.Second
+	}
+	if _, err := os.Stat(c.kubeconfigPath); err != nil {
+		return false
+	}
+	ctx, cancel := context.WithTimeout(context.Background(), 10*time.Second)
+	defer cancel()
+
+	// jsonpath emits one line per pod: <phase>|<startTime>
+	cmd := exec.CommandContext(ctx, "kubectl",
+		"--kubeconfig", c.kubeconfigPath,
+		"get", "pods", "-n", "kube-system",
+		"-o", `jsonpath={range .items[*]}{.status.phase}|{.status.startTime}{"\n"}{end}`,
+	)
+	out, err := cmd.Output()
+	if err != nil {
+		return false
+	}
+	lines := strings.Split(strings.TrimSpace(string(out)), "\n")
+	if len(lines) == 0 || lines[0] == "" {
+		// No pods reported. Conservatively treat as not-ready: kube-system
+		// is expected to host at least CoreDNS + pause.
+		return false
+	}
+	now := time.Now()
+	for _, line := range lines {
+		parts := strings.SplitN(line, "|", 2)
+		phase := strings.TrimSpace(parts[0])
+		if phase != "Running" {
+			return false
+		}
+		if len(parts) < 2 {
+			return false
+		}
+		start, perr := time.Parse(time.RFC3339, strings.TrimSpace(parts[1]))
+		if perr != nil {
+			return false
+		}
+		if now.Sub(start) < settle {
+			return false
+		}
+	}
+	return true
+}
+
+// CheckProbeURL fetches the given URL and reports whether it returned 200.
+// Empty url returns (true, nil) — the check is opt-in.
+func CheckProbeURL(url string) (bool, error) {
+	if url == "" {
+		return true, nil
+	}
+	client := &http.Client{Timeout: 5 * time.Second}
+	resp, err := client.Get(url)
+	if err != nil {
+		return false, fmt.Errorf("probe URL %s: %w", url, err)
+	}
+	defer resp.Body.Close()
+	return resp.StatusCode == http.StatusOK, nil
+}
+
+// CheckDiskWritable writes a small file under dataDir, fsyncs, reads it back,
+// and removes it. Confirms the data partition is mounted read-write and the
+// underlying disk is responsive. Empty dataDir defaults to /var/lib/kubesolo.
+func CheckDiskWritable(dataDir string) (bool, error) {
+	if dataDir == "" {
+		dataDir = "/var/lib/kubesolo"
+	}
+	if _, err := os.Stat(dataDir); err != nil {
+		// Data partition not mounted? That's catastrophic but we shouldn't
+		// claim the disk is fine.
+		return false, fmt.Errorf("dataDir %s: %w", dataDir, err)
+	}
+	probe := filepath.Join(dataDir, ".update-probe")
+	want := []byte("kubesolo-os healthcheck probe")
+
+	f, err := os.Create(probe)
+	if err != nil {
+		return false, fmt.Errorf("create probe: %w", err)
+	}
+	defer os.Remove(probe)
+
+	if _, err := f.Write(want); err != nil {
+		f.Close()
+		return false, fmt.Errorf("write probe: %w", err)
+	}
+	if err := f.Sync(); err != nil {
+		f.Close()
+		return false, fmt.Errorf("fsync probe: %w", err)
+	}
+	if err := f.Close(); err != nil {
+		return false, fmt.Errorf("close probe: %w", err)
+	}
+
+	got, err := os.ReadFile(probe)
+	if err != nil {
+		return false, fmt.Errorf("read probe: %w", err)
+	}
+	if string(got) != string(want) {
+		return false, fmt.Errorf("probe content mismatch: got %q", got)
+	}
+	return true, nil
+}

update/pkg/health/extended_test.go

@@ -0,0 +1,77 @@
+package health
+
+import (
+	"net/http"
+	"net/http/httptest"
+	"os"
+	"path/filepath"
+	"testing"
+)
+
+func TestCheckProbeURLEmptyAlwaysPasses(t *testing.T) {
+	ok, err := CheckProbeURL("")
+	if err != nil {
+		t.Fatalf("CheckProbeURL(\"\"): %v", err)
+	}
+	if !ok {
+		t.Error("empty probe URL should return ok=true (check disabled)")
+	}
+}
+
+func TestCheckProbeURL200(t *testing.T) {
+	srv := httptest.NewServer(http.HandlerFunc(func(w http.ResponseWriter, r *http.Request) {
+		w.WriteHeader(http.StatusOK)
+	}))
+	defer srv.Close()
+	ok, err := CheckProbeURL(srv.URL)
+	if err != nil {
+		t.Fatalf("CheckProbeURL: %v", err)
+	}
+	if !ok {
+		t.Error("expected ok=true on 200")
+	}
+}
+
+func TestCheckProbeURLNon200(t *testing.T) {
+	srv := httptest.NewServer(http.HandlerFunc(func(w http.ResponseWriter, r *http.Request) {
+		w.WriteHeader(http.StatusServiceUnavailable)
+	}))
+	defer srv.Close()
+	ok, err := CheckProbeURL(srv.URL)
+	if err != nil {
+		t.Fatalf("CheckProbeURL: %v", err)
+	}
+	if ok {
+		t.Error("expected ok=false on 503")
+	}
+}
+
+func TestCheckProbeURLNetworkError(t *testing.T) {
+	// Port 1 is reserved (tcpmux) and never bound by Linux defaults.
+	_, err := CheckProbeURL("http://127.0.0.1:1")
+	if err == nil {
+		t.Error("expected error for unreachable URL, got nil")
+	}
+}
+
+func TestCheckDiskWritableHappyPath(t *testing.T) {
+	dir := t.TempDir()
+	ok, err := CheckDiskWritable(dir)
+	if err != nil {
+		t.Fatalf("CheckDiskWritable: %v", err)
+	}
+	if !ok {
+		t.Error("expected ok=true on writable temp dir")
+	}
+	// Probe file should have been cleaned up.
+	if _, err := os.Stat(filepath.Join(dir, ".update-probe")); !os.IsNotExist(err) {
+		t.Errorf("probe file not cleaned up: stat err=%v", err)
+	}
+}
+
+func TestCheckDiskWritableMissingDir(t *testing.T) {
+	_, err := CheckDiskWritable("/this/path/does/not/exist")
+	if err == nil {
+		t.Error("expected error for missing dataDir, got nil")
+	}
+}

update/pkg/health/health.go

@@ -24,15 +24,20 @@ import (
 
 // Status represents the result of a health check.
 type Status struct {
-	Containerd bool
-	APIServer  bool
-	NodeReady  bool
-	Message    string
+	Containerd       bool
+	APIServer        bool
+	NodeReady        bool
+	KubeSystemReady  bool // optional — true unless KubeSystemSettle is non-zero
+	ProbeURL         bool // optional — true unless ProbeURL is set
+	DiskWritable     bool // optional — true unless DataDir is set
+	Message          string
 }
 
-// IsHealthy returns true if all checks passed.
+// IsHealthy returns true if all required checks passed. Optional checks
+// default to true when not configured, so they don't block the result.
 func (s *Status) IsHealthy() bool {
-	return s.Containerd && s.APIServer && s.NodeReady
+	return s.Containerd && s.APIServer && s.NodeReady &&
+		s.KubeSystemReady && s.ProbeURL && s.DiskWritable
 }
 
 // Checker performs health checks against the local KubeSolo instance.
@@ -40,6 +45,11 @@ type Checker struct {
 	kubeconfigPath string
 	apiServerAddr  string
 	timeout        time.Duration
+
+	// Optional gates. Zero values disable the check (it reports true).
+	KubeSystemSettle time.Duration
+	ProbeURL         string
+	DataDir          string
 }
 
 // NewChecker creates a health checker.
@@ -149,12 +159,37 @@ func (c *Checker) CheckNodeReady() bool {
 }
 
 // RunAll performs all health checks and returns the combined status.
+//
+// Optional checks (kube-system settle, user probe URL, disk writability) are
+// only run if the corresponding Checker fields are set; otherwise they
+// report true so as not to block the result.
 func (c *Checker) RunAll() *Status {
-	return &Status{
-		Containerd: c.CheckContainerd(),
-		APIServer:  c.CheckAPIServer(),
-		NodeReady:  c.CheckNodeReady(),
+	s := &Status{
+		Containerd:      c.CheckContainerd(),
+		APIServer:       c.CheckAPIServer(),
+		NodeReady:       c.CheckNodeReady(),
+		KubeSystemReady: true,
+		ProbeURL:        true,
+		DiskWritable:    true,
 	}
+	if c.KubeSystemSettle > 0 {
+		s.KubeSystemReady = c.CheckKubeSystemReady(c.KubeSystemSettle)
+	}
+	if c.ProbeURL != "" {
+		ok, err := CheckProbeURL(c.ProbeURL)
+		if err != nil {
+			slog.Warn("probe URL check failed", "url", c.ProbeURL, "error", err)
+		}
+		s.ProbeURL = ok
+	}
+	if c.DataDir != "" {
+		ok, err := CheckDiskWritable(c.DataDir)
+		if err != nil {
+			slog.Warn("disk writability check failed", "dir", c.DataDir, "error", err)
+		}
+		s.DiskWritable = ok
+	}
+	return s
 }
 
 // WaitForHealthy polls health checks until all pass or timeout expires.

update/pkg/health/health_test.go

@@ -6,36 +6,42 @@ import (
 )
 
 func TestStatusIsHealthy(t *testing.T) {
+	// Helper for the new 6-field Status: all-true except the named one.
+	allBut := func(field string) Status {
+		s := Status{
+			Containerd: true, APIServer: true, NodeReady: true,
+			KubeSystemReady: true, ProbeURL: true, DiskWritable: true,
+		}
+		switch field {
+		case "Containerd":
+			s.Containerd = false
+		case "APIServer":
+			s.APIServer = false
+		case "NodeReady":
+			s.NodeReady = false
+		case "KubeSystemReady":
+			s.KubeSystemReady = false
+		case "ProbeURL":
+			s.ProbeURL = false
+		case "DiskWritable":
+			s.DiskWritable = false
+		}
+		return s
+	}
+
 	tests := []struct {
 		name       string
 		status     Status
 		wantHealth bool
 	}{
-		{
-			name:       "all healthy",
-			status:     Status{Containerd: true, APIServer: true, NodeReady: true},
-			wantHealth: true,
-		},
-		{
-			name:       "containerd down",
-			status:     Status{Containerd: false, APIServer: true, NodeReady: true},
-			wantHealth: false,
-		},
-		{
-			name:       "apiserver down",
-			status:     Status{Containerd: true, APIServer: false, NodeReady: true},
-			wantHealth: false,
-		},
-		{
-			name:       "node not ready",
-			status:     Status{Containerd: true, APIServer: true, NodeReady: false},
-			wantHealth: false,
-		},
-		{
-			name:       "all down",
-			status:     Status{Containerd: false, APIServer: false, NodeReady: false},
-			wantHealth: false,
-		},
+		{"all healthy", allBut(""), true},
+		{"containerd down", allBut("Containerd"), false},
+		{"apiserver down", allBut("APIServer"), false},
+		{"node not ready", allBut("NodeReady"), false},
+		{"kube-system not ready", allBut("KubeSystemReady"), false},
+		{"probe URL failed", allBut("ProbeURL"), false},
+		{"disk not writable", allBut("DiskWritable"), false},
+		{"all down", Status{}, false},
 	}
 
 	for _, tt := range tests {

update/pkg/health/preflight.go

@@ -0,0 +1,51 @@
+package health
+
+import (
+	"context"
+	"fmt"
+	"os"
+	"os/exec"
+	"strings"
+	"time"
+)
+
+// NodeBlockLabel is the well-known label that workload authors set on the
+// local node to defer an OS update. When present and "true", apply refuses.
+const NodeBlockLabel = "updates.kubesolo.io/block"
+
+// CheckNodeBlocked returns (blocked, error). blocked==true means the local
+// node carries the updates.kubesolo.io/block=true label and the caller should
+// refuse the update.
+//
+// If the kubeconfig is not available (offline / pre-boot / air-gap), this
+// returns (false, nil) — silently allowing the update. That's the safe
+// behaviour for the air-gap case where the node may not be reachable from
+// the agent's perspective.
+func CheckNodeBlocked(kubeconfigPath string) (bool, error) {
+	if kubeconfigPath == "" {
+		kubeconfigPath = "/var/lib/kubesolo/pki/admin/admin.kubeconfig"
+	}
+	if _, err := os.Stat(kubeconfigPath); err != nil {
+		// No kubeconfig — assume air-gap / pre-K8s. Don't block updates.
+		return false, nil
+	}
+
+	// Query the node label via kubectl. We don't know the node name a
+	// priori, so we use --kubeconfig on the local admin config and ask for
+	// "the only node" (KubeSolo is single-node by design).
+	ctx, cancel := context.WithTimeout(context.Background(), 10*time.Second)
+	defer cancel()
+
+	cmd := exec.CommandContext(ctx, "kubectl",
+		"--kubeconfig", kubeconfigPath,
+		"get", "node",
+		"-o", `jsonpath={.items[0].metadata.labels.updates\.kubesolo\.io/block}`)
+	out, err := cmd.Output()
+	if err != nil {
+		// API unreachable or no nodes — treat as not blocked (analogous to
+		// the kubeconfig-missing case). We still surface the error so the
+		// caller can decide to log it.
+		return false, fmt.Errorf("query node label: %w", err)
+	}
+	return strings.TrimSpace(string(out)) == "true", nil
+}

update/pkg/partition/freespace.go

@@ -0,0 +1,34 @@
+package partition
+
+import (
+	"fmt"
+	"syscall"
+)
+
+// FreeBytes returns the number of free bytes available on the filesystem
+// containing `path`. Uses statfs(2); path must exist and be readable.
+func FreeBytes(path string) (uint64, error) {
+	var stat syscall.Statfs_t
+	if err := syscall.Statfs(path, &stat); err != nil {
+		return 0, fmt.Errorf("statfs %s: %w", path, err)
+	}
+	// Bavail is the count of free blocks available to non-root users —
+	// matches what `df` reports. Bsize is the block size in bytes.
+	//nolint:unconvert // Bavail is uint64 on most platforms but int64 on darwin/freebsd
+	return uint64(stat.Bavail) * uint64(stat.Bsize), nil
+}
+
+// HasFreeSpaceFor reports whether `path`'s filesystem has at least `wantBytes`
+// of free space, with `headroomPct` reserved (e.g. 10 = require 110% of want).
+// Returns the available bytes alongside, so callers can render a useful error.
+func HasFreeSpaceFor(path string, wantBytes int64, headroomPct int) (avail uint64, ok bool, err error) {
+	avail, err = FreeBytes(path)
+	if err != nil {
+		return 0, false, err
+	}
+	if wantBytes < 0 {
+		return avail, false, fmt.Errorf("invalid wantBytes %d", wantBytes)
+	}
+	required := uint64(wantBytes) * uint64(100+headroomPct) / 100
+	return avail, avail >= required, nil
+}

update/pkg/partition/freespace_test.go

@@ -0,0 +1,44 @@
+package partition
+
+import "testing"
+
+func TestFreeBytesReturnsNonZeroOnTempDir(t *testing.T) {
+	b, err := FreeBytes(t.TempDir())
+	if err != nil {
+		t.Fatalf("FreeBytes: %v", err)
+	}
+	// On any sane test runner the temp filesystem has more than 1 KiB free.
+	if b < 1024 {
+		t.Errorf("FreeBytes = %d, want > 1024 on /tmp", b)
+	}
+}
+
+func TestFreeBytesNonExistentPath(t *testing.T) {
+	_, err := FreeBytes("/this/path/does/not/exist/at/all")
+	if err == nil {
+		t.Error("expected error for missing path, got nil")
+	}
+}
+
+func TestHasFreeSpaceForRejectsHugeRequest(t *testing.T) {
+	// Request 1 PiB with 10% headroom on /tmp — no test runner has that
+	// much free, so this should consistently report not-enough.
+	avail, ok, err := HasFreeSpaceFor(t.TempDir(), 1<<50, 10)
+	if err != nil {
+		t.Fatalf("HasFreeSpaceFor: %v", err)
+	}
+	if ok {
+		t.Errorf("expected insufficient space for 1PiB, got avail=%d ok=true", avail)
+	}
+}
+
+func TestHasFreeSpaceForAcceptsSmallRequest(t *testing.T) {
+	// 1 KiB with 10% headroom = 1.1 KiB. Any temp dir has this.
+	_, ok, err := HasFreeSpaceFor(t.TempDir(), 1024, 10)
+	if err != nil {
+		t.Fatalf("HasFreeSpaceFor: %v", err)
+	}
+	if !ok {
+		t.Error("expected sufficient space for 1KiB on /tmp")
+	}
+}

update/pkg/state/state.go

@@ -92,6 +92,12 @@ type UpdateState struct {
 	// AttemptCount counts attempts at the current ToVersion. Reset when
 	// ToVersion changes or on successful completion.
 	AttemptCount int `json:"attempt_count"`
+
+	// HealthCheckFailures counts consecutive post-Activated healthcheck
+	// failures. Reset to 0 on a successful healthcheck or after a rollback.
+	// Used by `kubesolo-update healthcheck --auto-rollback-after N` to
+	// trigger automatic recovery on a wedged new boot.
+	HealthCheckFailures int `json:"health_check_failures,omitempty"`
 }
 
 // New returns a fresh Idle state with UpdatedAt set to now.