ESXi Upgrade failed with mpx.vmhba error.

Products

• VMware vSphere ESXi

Issue/Introduction

ESXi Upgrade fails with following error:  COMMAND: export MTOOLS_SKIP_CHECK=1 && mcopy -i /vmfs/devices/disks/mpx.vmhba:C0:T0:L0@@xxxxx -Do /tmp/bootloader-installer/usr/lib/vmware/bootloader-installer/safeboot64.efi ::/EFI/BOOT/BOOTx64.EFI 

On checking esxupdate logs:

YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: esximage.Errors.InstallationError: VMware_bootbank_esx-base_7.0.3-0.135.24585291: Failed to update bootloader: failed to execute mtools command:
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: COMMAND: export MTOOLS_SKIP_CHECK=1 && mcopy -i /vmfs/devices/disks/mpx.vmhba32:C0:T0:L0@@xxxxx -Do /tmp/bootloader-installer/usr/lib/vmware/bootloader-installer/safeboot64.efi ::/EFI/BOOT/BOOTx64.EFI
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: STDOUT:
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: STDERR: plain_io: Input/output error
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: buffer_flush: write: Invalid argument
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: Short write 111104 instead of 111560
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: plain_io: Input/output error
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: buffer_flush: write: Input/output error
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: error in fat_write: Input/output error
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: Streamcache allocation problem:: 5
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: plain_io: Input/output error
YYYY-MM-DDTHH:MM esxupdate: 534349: root: ERROR: buffer_flush: write: Input/output error

Environment

vSphere ESXi 7.x

vSphere ESXi 8.x

Cause

The system encountered multiple input/output (I/O) errors when attempting to write to the boot disk mpx.vmhbaxx:Cx:Tx:Lx and we suspect that the issue is with the bootbank.

Resolution

If local drive is used to boot the ESXi host, then engage your Hardware team for further assistance. However, if USB is used to boot the ESXi host then have it changed.