Esxi patch updating failing with error "[VibFormatError] VIB 'nsx-adf-9.0.1.0-9.0.24952112' has invalid payload: Uncompressed size is required for payload 'nsx-adf' in a Quick Patch VIB."

Products

• VMware vSphere ESXi

Issue/Introduction

Attempting to patch ESXi from version 9.0 to 9.0.1 fails when using a custom ISO, and the following error is displayed:

[VibFormatError]
VIB 'nsx-adf-9.0.1.0-9.0.24952112' has invalid payload: Uncompressed size is required for payload 'nsx-adf' in a Quick Patch VIB.
filename = nsx-adf-9.0.1.0-9.0.24952112
Please refer to the log file for more details.

Actual size of the VIB nsx-adf-9.0.1.0-9.0.24952112 is 121 KB, whereas the VIB included in the custom image is only 118 KB.

Environment

vSphere ESXi 9.0
vSphere ESXi 9.1

Cause

The size mismatch indicates that the custom image contains a corrupted or incomplete VIB package, causing payload validation to fail during the ESXi patch process.

Resolution

Recreate the custom image using ESXi Image Builder from the vSphere Client and add the required VIBs again to ensure all components are complete and valid.

For more details, refer to:
https://techdocs.broadcom.com/us/en/vmware-cis/vsphere/vsphere/9-0/esx-installation-and-setup/customizing-installations-with-esxi-image-builder-cli.html