fix: Detect pod configuration errors early instead of timeout

pkg/apis/pipeline/v1/taskrun_types.go

@@ -212,6 +212,10 @@ const (
 	TaskRunReasonResolvingStepActionRef = "ResolvingStepActionRef"
 	// TaskRunReasonImagePullFailed is the reason set when the step of a task fails due to image not being pulled
 	TaskRunReasonImagePullFailed TaskRunReason = "TaskRunImagePullFailed"
+	// TaskRunReasonCreateContainerConfigError is the reason set when the step of a task fails due to config error (e.g., missing ConfigMap or Secret)
+	TaskRunReasonCreateContainerConfigError TaskRunReason = "CreateContainerConfigError"
+	// TaskRunReasonPodCreationFailed is the reason set when the pod backing the TaskRun fails to be created (e.g., CreateContainerError)
+	TaskRunReasonPodCreationFailed TaskRunReason = "PodCreationFailed"
 	// TaskRunReasonResultLargerThanAllowedLimit is the reason set when one of the results exceeds its maximum allowed limit of 1 KB
 	TaskRunReasonResultLargerThanAllowedLimit TaskRunReason = "TaskRunResultLargerThanAllowedLimit"
 	// TaskRunReasonStopSidecarFailed indicates that the sidecar is not properly stopped.

pkg/pod/status.go

@@ -827,28 +827,43 @@ func IsPodExceedingNodeResources(pod *corev1.Pod) bool {
 	return false
 }
 
-// isPodHitConfigError returns true if the Pod's status undicates there are config error raised
-func isPodHitConfigError(pod *corev1.Pod) bool {
+// hasContainerWaitingReason checks if any container (init or regular) is waiting with a reason
+// that matches the provided predicate function
+func hasContainerWaitingReason(pod *corev1.Pod, predicate func(corev1.ContainerStateWaiting) bool) bool {
+	// Check init containers first
+	for _, containerStatus := range pod.Status.InitContainerStatuses {
+		if containerStatus.State.Waiting != nil && predicate(*containerStatus.State.Waiting) {
+			return true
+		}
+	}
+	// Check regular containers
 	for _, containerStatus := range pod.Status.ContainerStatuses {
-		if containerStatus.State.Waiting != nil && containerStatus.State.Waiting.Reason == ReasonCreateContainerConfigError {
-			// for subPath directory creation errors, we want to allow recovery
-			if strings.Contains(containerStatus.State.Waiting.Message, "failed to create subPath directory") {
-				return false
-			}
+		if containerStatus.State.Waiting != nil && predicate(*containerStatus.State.Waiting) {
 			return true
 		}
 	}
 	return false
 }
 
+// isPodHitConfigError returns true if the Pod's status indicates there are config error raised
+func isPodHitConfigError(pod *corev1.Pod) bool {
+	return hasContainerWaitingReason(pod, func(waiting corev1.ContainerStateWaiting) bool {
+		if waiting.Reason != ReasonCreateContainerConfigError {
+			return false
+		}
+		// for subPath directory creation errors, we want to allow recovery
+		if strings.Contains(waiting.Message, "failed to create subPath directory") {
+			return false
+		}
+		return true
+	})
+}
+
 // isPullImageError returns true if the Pod's status indicates there are any error when pulling image
 func isPullImageError(pod *corev1.Pod) bool {
-	for _, containerStatus := range pod.Status.ContainerStatuses {
-		if containerStatus.State.Waiting != nil && isImageErrorReason(containerStatus.State.Waiting.Reason) {
-			return true
-		}
-	}
-	return false
+	return hasContainerWaitingReason(pod, func(waiting corev1.ContainerStateWaiting) bool {
+		return isImageErrorReason(waiting.Reason)
+	})
 }
 
 func isImageErrorReason(reason string) bool {

pkg/reconciler/taskrun/taskrun.go

@@ -97,16 +97,26 @@ type Reconciler struct {
 	tracerProvider           trace.TracerProvider
 }
 
-const ImagePullBackOff = "ImagePullBackOff"
+const (
+	ImagePullBackOff           = "ImagePullBackOff"
+	InvalidImageName           = "InvalidImageName"           // Invalid image reference
+	CreateContainerConfigError = "CreateContainerConfigError" // Missing ConfigMap/Secret, invalid env vars, etc.
+	CreateContainerError       = "CreateContainerError"       // Other container creation failures
+	ErrImagePull               = "ErrImagePull"               // Initial image pull failure
+)
 
 var (
 	// Check that our Reconciler implements taskrunreconciler.Interface
 	_ taskrunreconciler.Interface = (*Reconciler)(nil)
 
 	// Pod failure reasons that trigger failure of the TaskRun
+	// Note: ErrImagePull is intentionally not included as it's a transient state
+	// that Kubernetes will automatically retry before transitioning to ImagePullBackOff
 	podFailureReasons = map[string]struct{}{
-		ImagePullBackOff:   {},
-		"InvalidImageName": {},
+		ImagePullBackOff:           {},
+		InvalidImageName:           {},
+		CreateContainerConfigError: {},
+		CreateContainerError:       {},
 	}
 )
 
@@ -247,66 +257,101 @@ func (c *Reconciler) ReconcileKind(ctx context.Context, tr *v1.TaskRun) pkgrecon
 }
 
 func (c *Reconciler) checkPodFailed(ctx context.Context, tr *v1.TaskRun) (bool, v1.TaskRunReason, string) {
-	imagePullBackOffTimeoutPodConditions := []string{string(corev1.PodInitialized), "PodReadyToStartContainers"}
 	for _, step := range tr.Status.Steps {
-		if step.Waiting != nil {
-			if _, found := podFailureReasons[step.Waiting.Reason]; found {
-				if step.Waiting.Reason == ImagePullBackOff {
-					imagePullBackOffTimeOut := config.FromContextOrDefaults(ctx).Defaults.DefaultImagePullBackOffTimeout
-					// only attempt to recover from the imagePullBackOff if specified
-					if imagePullBackOffTimeOut.Seconds() != 0 {
-						p, err := c.KubeClientSet.CoreV1().Pods(tr.Namespace).Get(ctx, tr.Status.PodName, metav1.GetOptions{})
-						if err != nil {
-							message := fmt.Sprintf(`the step %q in TaskRun %q failed to pull the image %q and the pod with error: "%s."`, step.Name, tr.Name, step.ImageID, err)
-							return true, v1.TaskRunReasonImagePullFailed, message
-						}
-						for _, condition := range p.Status.Conditions {
-							// check the pod condition to get the time when the pod was ready to start containers / initialized.
-							// keep trying until the pod schedule time has exceeded the specified imagePullBackOff timeout duration
-							if slices.Contains(imagePullBackOffTimeoutPodConditions, string(condition.Type)) {
-								if c.Clock.Since(condition.LastTransitionTime.Time) < imagePullBackOffTimeOut {
-									return false, "", ""
-								}
-							}
-						}
-					}
-				}
-				image := step.ImageID
-				message := fmt.Sprintf(`the step %q in TaskRun %q failed to pull the image %q. The pod errored with the message: "%s."`, step.Name, tr.Name, image, step.Waiting.Message)
-				return true, v1.TaskRunReasonImagePullFailed, message
-			}
+		if step.Waiting == nil {
+			continue
+		}
+
+		if _, found := podFailureReasons[step.Waiting.Reason]; !found {
+			continue
+		}
+
+		failed, reason, message := c.checkContainerFailure(
+			ctx,
+			tr,
+			step.Waiting,
+			step.Name,
+			step.ImageID,
+			"step",
+		)
+		if failed {
+			return true, reason, message
 		}
 	}
+
 	for _, sidecar := range tr.Status.Sidecars {
-		if sidecar.Waiting != nil {
-			if _, found := podFailureReasons[sidecar.Waiting.Reason]; found {
-				if sidecar.Waiting.Reason == ImagePullBackOff {
-					imagePullBackOffTimeOut := config.FromContextOrDefaults(ctx).Defaults.DefaultImagePullBackOffTimeout
-					// only attempt to recover from the imagePullBackOff if specified
-					if imagePullBackOffTimeOut.Seconds() != 0 {
-						p, err := c.KubeClientSet.CoreV1().Pods(tr.Namespace).Get(ctx, tr.Status.PodName, metav1.GetOptions{})
-						if err != nil {
-							message := fmt.Sprintf(`the sidecar %q in TaskRun %q failed to pull the image %q and the pod with error: "%s."`, sidecar.Name, tr.Name, sidecar.ImageID, err)
-							return true, v1.TaskRunReasonImagePullFailed, message
-						}
-						for _, condition := range p.Status.Conditions {
-							// check the pod condition to get the time when the pod was ready to start containers / initialized.
-							// keep trying until the pod schedule time has exceeded the specified imagePullBackOff timeout duration
-							if slices.Contains(imagePullBackOffTimeoutPodConditions, string(condition.Type)) {
-								if c.Clock.Since(condition.LastTransitionTime.Time) < imagePullBackOffTimeOut {
-									return false, "", ""
-								}
-							}
-						}
+		if sidecar.Waiting == nil {
+			continue
+		}
+
+		if _, found := podFailureReasons[sidecar.Waiting.Reason]; !found {
+			continue
+		}
+
+		failed, reason, message := c.checkContainerFailure(
+			ctx,
+			tr,
+			sidecar.Waiting,
+			sidecar.Name,
+			sidecar.ImageID,
+			"sidecar",
+		)
+		if failed {
+			return true, reason, message
+		}
+	}
+
+	return false, "", ""
+}
+
+func (c *Reconciler) checkContainerFailure(
+	ctx context.Context,
+	tr *v1.TaskRun,
+	waiting *corev1.ContainerStateWaiting,
+	name,
+	imageID,
+	containerType string,
+) (bool, v1.TaskRunReason, string) {
+	if waiting.Reason == ImagePullBackOff {
+		imagePullBackOffTimeOut := config.FromContextOrDefaults(ctx).Defaults.DefaultImagePullBackOffTimeout
+		// only attempt to recover from the imagePullBackOff if specified
+		if imagePullBackOffTimeOut.Seconds() != 0 {
+			p, err := c.KubeClientSet.CoreV1().Pods(tr.Namespace).Get(ctx, tr.Status.PodName, metav1.GetOptions{})
+			if err != nil {
+				message := fmt.Sprintf(`the %s %q in TaskRun %q failed to pull the image %q. Failed to get pod with error: "%s."`, containerType, name, tr.Name, imageID, err)
+				return true, v1.TaskRunReasonImagePullFailed, message
+			}
+			imagePullBackOffTimeoutPodConditions := []string{string(corev1.PodInitialized), "PodReadyToStartContainers"}
+			for _, condition := range p.Status.Conditions {
+				// check the pod condition to get the time when the pod was ready to start containers / initialized.
+				// keep trying until the pod schedule time has exceeded the specified imagePullBackOff timeout duration
+				if slices.Contains(imagePullBackOffTimeoutPodConditions, string(condition.Type)) {
+					if c.Clock.Since(condition.LastTransitionTime.Time) < imagePullBackOffTimeOut {
+						return false, "", ""
 					}
 				}
-				image := sidecar.ImageID
-				message := fmt.Sprintf(`the sidecar %q in TaskRun %q failed to pull the image %q. The pod errored with the message: "%s."`, sidecar.Name, tr.Name, image, sidecar.Waiting.Message)
-				return true, v1.TaskRunReasonImagePullFailed, message
 			}
 		}
+		// ImagePullBackOff timeout exceeded or not configured
+		message := fmt.Sprintf(`the %s %q in TaskRun %q failed to pull the image %q. The pod errored with the message: "%s."`, containerType, name, tr.Name, imageID, waiting.Message)
+		return true, v1.TaskRunReasonImagePullFailed, message
 	}
-	return false, "", ""
+
+	// Handle CreateContainerConfigError (missing ConfigMap/Secret, invalid env vars, etc.)
+	if waiting.Reason == CreateContainerConfigError {
+		message := fmt.Sprintf(`the %s %q in TaskRun %q failed to start. The pod errored with the message: "%s."`, containerType, name, tr.Name, waiting.Message)
+		return true, v1.TaskRunReasonCreateContainerConfigError, message
+	}
+
+	// Handle InvalidImageName (unrecoverable error)
+	if waiting.Reason == InvalidImageName {
+		message := fmt.Sprintf(`the %s %q in TaskRun %q failed to pull the image %q. The pod errored with the message: "%s."`, containerType, name, tr.Name, imageID, waiting.Message)
+		return true, v1.TaskRunReasonImagePullFailed, message
+	}
+
+	// Handle CreateContainerError and other generic failures
+	message := fmt.Sprintf(`the %s %q in TaskRun %q failed to start. The pod errored with the message: "%s."`, containerType, name, tr.Name, waiting.Message)
+	return true, v1.TaskRunReasonPodCreationFailed, message
 }
 
 func (c *Reconciler) durationAndCountMetrics(ctx context.Context, tr *v1.TaskRun, beforeCondition *apis.Condition) {

pkg/reconciler/taskrun/taskrun_test.go

@@ -2846,8 +2846,8 @@ status:
 				}
 				// the error message includes the error if the pod is not found
 				if tc.podNotFound {
-					expectedStatus.Message = fmt.Sprintf(`the %s "unnamed-%d" in TaskRun "test-imagepull-fail" failed to pull the image "whatever" and the pod with error: "%s."`, tc.failure, stepNumber, tc.message)
-					wantEvents[1] = fmt.Sprintf(`Warning Failed the %s "unnamed-%d" in TaskRun "test-imagepull-fail" failed to pull the image "whatever" and the pod with error: "%s.`, tc.failure, stepNumber, tc.message)
+					expectedStatus.Message = fmt.Sprintf(`the %s "unnamed-%d" in TaskRun "test-imagepull-fail" failed to pull the image "whatever". Failed to get pod with error: "%s."`, tc.failure, stepNumber, tc.message)
+					wantEvents[1] = fmt.Sprintf(`Warning Failed the %s "unnamed-%d" in TaskRun "test-imagepull-fail" failed to pull the image "whatever". Failed to get pod with error: "%s.`, tc.failure, stepNumber, tc.message)
 				}
 				condition := newTr.Status.GetCondition(apis.ConditionSucceeded)
 				if d := cmp.Diff(expectedStatus, condition, ignoreLastTransitionTime); d != "" {
@@ -2862,6 +2862,132 @@ status:
 	}
 }
 
+func TestReconcileContainerFailures(t *testing.T) {
+	testCases := []struct {
+		name           string
+		reason         string
+		message        string
+		containerType  string
+		expectedReason v1.TaskRunReason
+	}{{
+		name:           "CreateContainerConfigError for step - missing configmap",
+		reason:         "CreateContainerConfigError",
+		message:        "configmap \"config-for-testing\" not found",
+		containerType:  "step",
+		expectedReason: "CreateContainerConfigError",
+	}, {
+		name:           "CreateContainerConfigError for sidecar - missing secret",
+		reason:         "CreateContainerConfigError",
+		message:        "secret \"secret-for-testing\" not found",
+		containerType:  "sidecar",
+		expectedReason: "CreateContainerConfigError",
+	}, {
+		name:           "CreateContainerError for step",
+		reason:         "CreateContainerError",
+		message:        "failed to create container",
+		containerType:  "step",
+		expectedReason: "PodCreationFailed",
+	}, {
+		name:           "CreateContainerError for sidecar",
+		reason:         "CreateContainerError",
+		message:        "failed to create container",
+		containerType:  "sidecar",
+		expectedReason: "PodCreationFailed",
+	}, {
+		name:           "InvalidImageName for step",
+		reason:         "InvalidImageName",
+		message:        "invalid image reference",
+		containerType:  "step",
+		expectedReason: "TaskRunImagePullFailed",
+	}, {
+		name:           "InvalidImageName for sidecar",
+		reason:         "InvalidImageName",
+		message:        "invalid image reference",
+		containerType:  "sidecar",
+		expectedReason: "TaskRunImagePullFailed",
+	}}
+
+	for _, tc := range testCases {
+		t.Run(tc.name, func(t *testing.T) {
+			taskRun := parse.MustParseV1TaskRun(t, `
+metadata:
+  name: test-container-failure
+  namespace: foo
+spec:
+  taskSpec:
+    sidecars:
+    - image: busybox
+    steps:
+    - image: alpine
+status:
+  podName: "test-pod"
+  sidecars:
+  - container: sidecar-busybox
+    name: busybox
+    imageID: docker.io/library/busybox:latest
+  steps:
+  - container: step-alpine
+    name: alpine
+    imageID: docker.io/library/alpine:latest
+`)
+
+			// Set the waiting state based on container type
+			if tc.containerType == "step" {
+				taskRun.Status.Steps[0].Waiting = &corev1.ContainerStateWaiting{
+					Reason:  tc.reason,
+					Message: tc.message,
+				}
+			} else {
+				taskRun.Status.Sidecars[0].Waiting = &corev1.ContainerStateWaiting{
+					Reason:  tc.reason,
+					Message: tc.message,
+				}
+			}
+
+			d := test.Data{
+				TaskRuns: []*v1.TaskRun{taskRun},
+			}
+
+			testAssets, cancel := getTaskRunController(t, d)
+			defer cancel()
+
+			// Reconcile the TaskRun
+			if err := testAssets.Controller.Reconciler.Reconcile(testAssets.Ctx, getRunName(taskRun)); err != nil {
+				t.Fatalf("Unexpected error reconciling TaskRun: %v", err)
+			}
+
+			// Verify the TaskRun failed with the expected reason
+			reconciledTr, err := testAssets.Clients.Pipeline.TektonV1().TaskRuns(taskRun.Namespace).Get(
+				testAssets.Ctx, taskRun.Name, metav1.GetOptions{},
+			)
+			if err != nil {
+				t.Fatalf("Failed to get reconciled TaskRun: %v", err)
+			}
+
+			condition := reconciledTr.Status.GetCondition(apis.ConditionSucceeded)
+			if condition == nil {
+				t.Fatal("TaskRun should have a Succeeded condition")
+			}
+
+			if condition.Status != corev1.ConditionFalse {
+				t.Errorf("Expected TaskRun to fail, but status is: %v", condition.Status)
+			}
+
+			if condition.Reason != string(tc.expectedReason) {
+				t.Errorf("Expected reason %q, got %q", tc.expectedReason, condition.Reason)
+			}
+
+			if !strings.Contains(condition.Message, tc.message) {
+				t.Errorf("Expected message to contain %q, got: %q", tc.message, condition.Message)
+			}
+
+			if !strings.Contains(condition.Message, tc.containerType) {
+				t.Errorf("Expected message to mention container type %q, got: %q", tc.containerType, condition.Message)
+			}
+		})
+	}
+}
+
 func TestReconcileWithTimeoutDisabled(t *testing.T) {
 	type testCase struct {
 		name    string