Install VMware ESX 4 From USB

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

Step by step

1. Download ESX-4.1.0-update01-348481.iso or from VMware vSphere 4
2. 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
   

3. Mounting the USB partition

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

4. Mounting the ESX-4.1.0-update01-348481.iso

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

5. 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
   

6. 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
   

7. 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
   

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

Done