Install VMware ESX 4 From USB

Install ESX-4.1.0-update01-348481 From USB Flash Disk

Step by step

Download ESX-4.1.0-update01-348481.iso or from VMware vSphere 4
Create Partition and Format USB Flash Disk (Assume USB device: /dev/sdb and USB partition: /dev/sdb1)
```
$ umount /dev/sdb1
$ fdisk /dev/sdb
$ mkfs.ext3 -L ESX410-348481 /dev/sdb1
```

Mounting the USB partition

$ mkdir /media/ESX410-348481
$ mount -o rw /dev/sdb1 /media/ESX410-348481

Mounting the ESX-4.1.0-update01-348481.iso

$ mkdir /media/isoimage
$ mount -o loop ESX-4.1.0-update01-348481.iso /media/isoimage

Copy the content of ESX-4.1.0-update01-348481.iso to USB partition

$ rsync -av /media/isoimage/ /media/ESX410-348481
$ find /media/ESX410-348481 -type d -perm 555 | xargs chmod 755
$ find /media/ESX410-348481 -type f -perm 555 | xargs chmod 755
$ find /media/ESX410-348481 -type f -perm 444 | xargs chmod 644
$ find /media/ESX410-348481 -type f -name 'TRANS.TBL' | xargs rm -fv

Make the USB Flash Disk Bootable (USB device: /dev/sdb)

$ extlinux --install /media/ESX410-348481/isolinux
$ rpm -ql syslinux | grep mbr.bin
/usr/share/syslinux/altmbr.bin
/usr/share/syslinux/gptmbr.bin
/usr/share/syslinux/mbr.bin
$ cat /usr/share/syslinux/mbr.bin > /dev/sdb
$ rpm -ql syslinux | grep menu.c32
/usr/share/syslinux/menu.c32
/usr/share/syslinux/vesamenu.c32
$ cd /media/ESX410-348481/isolinux
$ cp -av /usr/share/syslinux/menu.c32 ./
$ cp -av isolinux.cfg syslinux.cfg
$ cp -alv syslinux.cfg extlinux.conf

Edit file /media/ESX410-348481/isolinux/extlinux.conf

$ vi /media/ESX410-348481/isolinux/extlinux.conf

Replace the following lines

default esx
gfxboot bootlogo
prompt 1
#menu title ESX build 348481
timeout 300

LABEL esx-graphic
  menu default
  menu label Install ESX in graphical mode
  kernel vmlinuz
  append initrd=initrd.img debugLogToSerial=1 vmkConsole=false mem=512M quiet

With the following lines

default menu.c32
prompt 0
menu title ESX-4.1.0 Build 348481
timeout 100

LABEL esx-default
  menu label Default
  kernel vmlinuz
  append initrd=initrd.img debugLogToSerial=1 vmkConsole=false mem=512M quiet

LABEL esx-graphic
  menu label Install ESX in graphical mode
  kernel vmlinuz
  append initrd=initrd.img debugLogToSerial=1 vmkConsole=false mem=512M quiet askmedia

Make sure the content of /media/ESX410-348481/isolinux/syslinux.cfg and /media/ESX410-348481/isolinux/extlinux.conf identical.
Reboot and choose Boot Menu to boot from USB Disk

Done

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