fix: resolve .env from CWD and stop _do_deploy env mutation

src/runpod_flash/__init__.py

@@ -1,9 +1,11 @@
 __version__ = "1.8.0"  # x-release-please-version
 
 # Load .env vars from file before everything else
-from dotenv import load_dotenv
+# usecwd=True walks up from CWD (user's project) instead of from the
+# package source file location, which matters for editable installs.
+from dotenv import find_dotenv, load_dotenv
 
-load_dotenv()
+load_dotenv(find_dotenv(usecwd=True))
 
 from .logger import setup_logging  # noqa: E402
 

src/runpod_flash/core/resources/environment.py

@@ -1,5 +1,5 @@
 from typing import Dict, Optional
-from dotenv import dotenv_values
+from dotenv import dotenv_values, find_dotenv
 
 
 class EnvironmentVars:
@@ -16,7 +16,9 @@ def _load_env(self) -> Dict[str, str]:
             Dict[str, str]: Dictionary containing environment variables from .env file
         """
         # Use dotenv_values instead of load_dotenv to get only variables from .env
-        return dict(dotenv_values())
+        # usecwd=True walks up from CWD (user's project) instead of from the
+        # package source file location, which matters for editable installs.
+        return dict(dotenv_values(find_dotenv(usecwd=True)))
 
     def get_env(self) -> Dict[str, str]:
         """

src/runpod_flash/core/resources/load_balancer_sls_resource.py

@@ -255,10 +255,10 @@ async def _do_deploy(self) -> "LoadBalancerSlsResource":
             return self
 
         try:
-            # Mark this endpoint as load-balanced (triggers auto-provisioning on boot)
-            if self.env is None:
-                self.env = {}
-            self.env["FLASH_ENDPOINT_TYPE"] = "lb"
+            # NOTE: FLASH_ENDPOINT_TYPE is NOT injected here. For flash deploy,
+            # the runtime resource_provisioner sets it. For flash run (live
+            # serverless), the worker must NOT see it — otherwise it triggers
+            # artifact unpacking which doesn't exist for live endpoints.
 
             # Call parent deploy (creates endpoint via RunPod API)
             log.debug(f"Deploying LB endpoint: {self.name}")

src/runpod_flash/core/resources/serverless.py

@@ -259,20 +259,19 @@ def validate_python_version(cls, v: Optional[str]) -> Optional[str]:
 
     @property
     def config_hash(self) -> str:
-        """Get config hash excluding env and runtime-assigned fields.
+        """Get config hash excluding runtime-assigned fields.
 
         Prevents false drift from:
-        - Dynamic env vars computed at runtime
         - Runtime-assigned fields (template, templateId, aiKey, userId, etc.)
 
-        Only hashes user-specified configuration, not server-assigned state.
+        Hashes user-specified configuration including env vars.
         """
         import hashlib
         import json
 
         resource_type = self.__class__.__name__
 
-        # Exclude runtime fields, env, and id from hash
+        # Exclude runtime fields and id from hash
         exclude_fields = (
             self.__class__.RUNTIME_FIELDS | self.__class__.EXCLUDED_HASH_FIELDS
         )
@@ -534,12 +533,24 @@ def _payload_exclude(self) -> Set[str]:
 
     @staticmethod
     def _build_template_update_payload(
-        template: PodTemplate, template_id: str
+        template: PodTemplate,
+        template_id: str,
+        *,
+        skip_env: bool = False,
     ) -> Dict[str, Any]:
         """Build saveTemplate payload from template model.
 
         Keep this to fields supported by saveTemplate to avoid passing endpoint-only
         fields to the template mutation.
+
+        Args:
+            template: Template model with desired configuration.
+            template_id: ID of the template to update.
+            skip_env: When True, omit ``env`` from the payload so
+                saveTemplate preserves the existing template env vars.
+                This prevents removing platform-injected vars (e.g.
+                PORT, PORT_HEALTH on LB endpoints) when the user's
+                env hasn't actually changed.
         """
         template_data = template.model_dump(exclude_none=True, mode="json")
         allowed_fields = {
@@ -550,6 +561,8 @@ def _build_template_update_payload(
             "env",
             "readme",
         }
+        if skip_env:
+            allowed_fields.discard("env")
         payload = {
             key: value for key, value in template_data.items() if key in allowed_fields
         }
@@ -643,6 +656,56 @@ def _get_module_path(self) -> Optional[str]:
         except Exception:
             return None
 
+    def _inject_template_env(self, key: str, value: str) -> None:
+        """Append a KeyValuePair to self.template.env if the key isn't already present.
+
+        This injects runtime env vars directly into the template without
+        mutating self.env, which would cause false config drift on subsequent
+        deploys.
+        """
+        if self.template is None:
+            return
+        if self.template.env is None:
+            self.template.env = []
+        existing_keys = {kv.key for kv in self.template.env}
+        if key not in existing_keys:
+            self.template.env.append(KeyValuePair(key=key, value=value))
+
+    def _inject_runtime_template_vars(self) -> None:
+        """Inject runtime env vars into template.env without mutating self.env.
+
+        For QB endpoints making remote calls: injects RUNPOD_API_KEY.
+        For LB endpoints: injects FLASH_MODULE_PATH.
+
+        Called by both _do_deploy (initial) and update (env changes) so
+        runtime vars survive template updates.
+        """
+        env_dict = self.env or {}
+
+        if self.type == ServerlessType.QB:
+            if self._check_makes_remote_calls():
+                if "RUNPOD_API_KEY" not in env_dict:
+                    from runpod_flash.core.credentials import get_api_key
+
+                    api_key = get_api_key()
+                    if api_key:
+                        self._inject_template_env("RUNPOD_API_KEY", api_key)
+                        log.debug(
+                            f"{self.name}: Injected RUNPOD_API_KEY for remote calls "
+                            f"(makes_remote_calls=True)"
+                        )
+                    else:
+                        log.warning(
+                            f"{self.name}: makes_remote_calls=True but RUNPOD_API_KEY not set. "
+                            f"Remote calls to other endpoints will fail."
+                        )
+
+        elif self.type == ServerlessType.LB:
+            module_path = self._get_module_path()
+            if module_path and "FLASH_MODULE_PATH" not in env_dict:
+                self._inject_template_env("FLASH_MODULE_PATH", module_path)
+                log.debug(f"{self.name}: Injected FLASH_MODULE_PATH={module_path}")
+
     async def _do_deploy(self) -> "DeployableResource":
         """
         Deploys the serverless resource using the provided configuration.
@@ -658,43 +721,7 @@ async def _do_deploy(self) -> "DeployableResource":
                 log.debug(f"{self} exists")
                 return self
 
-            # Inject API key for queue-based endpoints that make remote calls
-            if self.type == ServerlessType.QB:
-                env_dict = self.env or {}
-
-                # Check if this resource makes remote calls (from build manifest)
-                makes_remote_calls = self._check_makes_remote_calls()
-
-                if makes_remote_calls:
-                    # Inject RUNPOD_API_KEY if not already set
-                    if "RUNPOD_API_KEY" not in env_dict:
-                        from runpod_flash.core.credentials import get_api_key
-
-                        api_key = get_api_key()
-                        if api_key:
-                            env_dict["RUNPOD_API_KEY"] = api_key
-                            log.debug(
-                                f"{self.name}: Injected RUNPOD_API_KEY for remote calls "
-                                f"(makes_remote_calls=True)"
-                            )
-                        else:
-                            log.warning(
-                                f"{self.name}: makes_remote_calls=True but RUNPOD_API_KEY not set. "
-                                f"Remote calls to other endpoints will fail."
-                            )
-
-                self.env = env_dict
-
-            # Inject module path for load-balanced endpoints
-            elif self.type == ServerlessType.LB:
-                env_dict = self.env or {}
-
-                module_path = self._get_module_path()
-                if module_path and "FLASH_MODULE_PATH" not in env_dict:
-                    env_dict["FLASH_MODULE_PATH"] = module_path
-                    log.debug(f"{self.name}: Injected FLASH_MODULE_PATH={module_path}")
-
-                self.env = env_dict
+            self._inject_runtime_template_vars()
 
             # Ensure network volume is deployed first
             await self._ensure_network_volume_deployed()
@@ -764,8 +791,29 @@ async def update(self, new_config: "ServerlessResource") -> "ServerlessResource"
 
                 if new_config.template:
                     if resolved_template_id:
+                        # Skip env in the template payload when the user's env
+                        # hasn't changed.  This lets the platform keep vars it
+                        # injected (e.g. PORT, PORT_HEALTH on LB endpoints)
+                        # and avoids a spurious rolling release.
+                        #
+                        # Also check template.env: if env is empty but the
+                        # caller provided explicit template env entries, those
+                        # must not be silently dropped.
+                        env_unchanged = self.env == new_config.env
+                        has_explicit_template_env = (
+                            not new_config.env and new_config.template.env is not None
+                        )
+                        skip_env = env_unchanged and not has_explicit_template_env
+
+                        if not skip_env:
+                            # Inject runtime vars (RUNPOD_API_KEY, FLASH_MODULE_PATH)
+                            # so they survive the template env overwrite.
+                            new_config._inject_runtime_template_vars()
+
                         template_payload = self._build_template_update_payload(
-                            new_config.template, resolved_template_id
+                            new_config.template,
+                            resolved_template_id,
+                            skip_env=skip_env,
                         )
                         await client.update_template(template_payload)
                         log.debug(