very large php string magically turns into array - php

Question

I am getting an "Array to string conversion error on PHP";
I am using the "variable" (that should be a string) as the third parameter to str_replace. So in summary (very simplified version of whats going on):
$str = "very long string";
str_replace("tag", $some_other_array, $str);
$str is throwing the error, and I have been trying to fix it all day, the thing I have tried is:
if(is_array($str)) die("its somehow an array");
serialize($str); //inserted this before str_replace call.
I have spent all day on it, and no its not something stupid like variables around the wrong way - it is something bizarre. I have even dumped it to a file and its a string.
My hypothesis:
The string is too long and php can't deal with it, turns into an array.
The $str value in this case is nested and called recursively, the general flow could be explained like this:
--code
//pass by reference
function the_function ($something, &$OFFENDING_VAR, $something_else) {
while(preg_match($something, $OFFENDING_VAR)) {
$OFFENDING_VAR = str_replace($x, y, $OFFENDING_VAR); // this is the error
}
}
So it may be something strange due to str_replace, but that would mean that at some point str_replace would have to return an array.
Please help me work this out, its very confusing and I have wasted a day on it.
---- ORIGINAL FUNCTION CODE -----
//This function gets called with multiple different "Target Variables" Target is the subject
//line, from and body of the email filled with << tags >> so the str_replace function knows
//where to replace them
function perform_replacements($replacements, &$target, $clean = TRUE,
$start_tag = '<<', $end_tag = '>>', $max_substitutions = 5) {
# Construct separate tag and replacement value arrays for use in the substitution loop.
$tags = array();
$replacement_values = array();
foreach ($replacements as $tag_text => $replacement_value) {
$tags[] = $start_tag . $tag_text . $end_tag;
$replacement_values[] = $replacement_value;
}
# TODO: this badly needs refactoring
# TODO: auto upgrade <<foo>> to <<foo_html>> if foo_html exists and acting on html template
# Construct a regular expression for use in scanning for tags.
$tag_match = '/' . preg_quote($start_tag) . '\w+' . preg_quote($end_tag) . '/';
# Perform the substitution until all valid tags are replaced, or the maximum substitutions
# limit is reached.
$substitution_count = 0;
while (preg_match ($tag_match, $target) && ($substitution_count++ < $max_substitutions)) {
$target = serialize($target);
$temp = str_replace($tags,
$replacement_values,
$target); //This is the line that is failing.
unset($target);
$target = $temp;
}
if ($clean) {
# Clean up any unused search values.
$target = preg_replace($tag_match, '', $target);
}
}

Answer 1

How do you know $str is the problem and not $some_other_array?
From the manual:
If search and replace are arrays, then str_replace() takes a value
from each array and uses them to search and replace on subject. If
replace has fewer values than search, then an empty string is used for
the rest of replacement values. If search is an array and replace is a
string, then this replacement string is used for every value of
search. The converse would not make sense, though.
The second parameter can only be an array if the first one is as well.