Unable to build ubuntu-22.04 runner image

[bvaughan527]

Description

When attempting to build a self-hosted image from the ubuntu-22.04 runner image the image build fails with the below pester test result.

==> azure-arm.build_image: FrameworkDuration : 00:00:02.6494306
==> azure-arm.build_image: Failed : {[-] Image has enough free space}
==> azure-arm.build_image: FailedBlocks : {}
==> azure-arm.build_image: FailedContainers : {}
==> azure-arm.build_image: Passed : {[+] /opt/actionarchivecache not empty, [+] /opt/action
==> azure-arm.build_image: archivecache/actions_cache/0057852bfaa89a56745cba8c7296
==> azure-arm.build_image: 529d2fc39830.tar.gz, [+] /opt/actionarchivecache/action
==> azure-arm.build_image: s_cache/0400d5f644dc74513175e3cd8d07132dd4860809.tar.gz
==> azure-arm.build_image: , [+] /opt/actionarchivecache/actions_cache/0865c47f36e
==> azure-arm.build_image: 68161719c5b124609996bb5c40129.tar.gz…}
==> azure-arm.build_image: Skipped : {}
==> azure-arm.build_image: Inconclusive : {}
==> azure-arm.build_image: NotRun : {}
==> azure-arm.build_image: Tests : {[+] /opt/actionarchivecache not empty, [+] /opt/action
==> azure-arm.build_image: archivecache/actions_cache/0057852bfaa89a56745cba8c7296
==> azure-arm.build_image: 529d2fc39830.tar.gz, [+] /opt/actionarchivecache/action
==> azure-arm.build_image: s_cache/0400d5f644dc74513175e3cd8d07132dd4860809.tar.gz
==> azure-arm.build_image: , [+] /opt/actionarchivecache/actions_cache/0865c47f36e
==> azure-arm.build_image: 68161719c5b124609996bb5c40129.tar.gz…}
==> azure-arm.build_image: CodeCoverage :
==> azure-arm.build_image:
==> azure-arm.build_image: Exception: Test run has failed

Platforms affected

• Azure DevOps
• GitHub Actions - Standard Runners
• GitHub Actions - Larger Runners

Runner images affected

• Ubuntu 22.04
• Ubuntu 24.04
• Ubuntu Slim
• macOS 13
• macOS 13 Arm64
• macOS 14
• macOS 14 Arm64
• macOS 15
• macOS 15 Arm64
• macOS 26 Arm64
• Windows Server 2019
• Windows Server 2022
• Windows Server 2025

Image version and build link

20251208.163.1

Is it regression?

Yes - Worked with image version: 20250929.60.1

Expected behavior

The ubuntu-22.04 packer build should successfully build the ubuntu-22.04 runner image and not fail.

Actual behavior

When building the ubuntu-22.04 runner image it fails with the below error message:

==> azure-arm.build_image: FrameworkDuration : 00:00:02.6494306
==> azure-arm.build_image: Failed : {[-] Image has enough free space}
==> azure-arm.build_image: FailedBlocks : {}
==> azure-arm.build_image: FailedContainers : {}
==> azure-arm.build_image: Passed : {[+] /opt/actionarchivecache not empty, [+] /opt/action
==> azure-arm.build_image: archivecache/actions_cache/0057852bfaa89a56745cba8c7296
==> azure-arm.build_image: 529d2fc39830.tar.gz, [+] /opt/actionarchivecache/action
==> azure-arm.build_image: s_cache/0400d5f644dc74513175e3cd8d07132dd4860809.tar.gz
==> azure-arm.build_image: , [+] /opt/actionarchivecache/actions_cache/0865c47f36e
==> azure-arm.build_image: 68161719c5b124609996bb5c40129.tar.gz…}
==> azure-arm.build_image: Skipped : {}
==> azure-arm.build_image: Inconclusive : {}
==> azure-arm.build_image: NotRun : {}
==> azure-arm.build_image: Tests : {[+] /opt/actionarchivecache not empty, [+] /opt/action
==> azure-arm.build_image: archivecache/actions_cache/0057852bfaa89a56745cba8c7296
==> azure-arm.build_image: 529d2fc39830.tar.gz, [+] /opt/actionarchivecache/action
==> azure-arm.build_image: s_cache/0400d5f644dc74513175e3cd8d07132dd4860809.tar.gz
==> azure-arm.build_image: , [+] /opt/actionarchivecache/actions_cache/0865c47f36e
==> azure-arm.build_image: 68161719c5b124609996bb5c40129.tar.gz…}
==> azure-arm.build_image: CodeCoverage :
==> azure-arm.build_image:
==> azure-arm.build_image: Exception: Test run has failed

Repro steps

Steps to reproduce the issue:

1. Follow steps at this link https://github.com/actions/runner-images/blob/main/docs/create-image-and-azure-resources.md to build a disk image.
2. Observe that the build fails.

[Alexey-Ayupov]

Hello @bvaughan527, we don't see this behavior in our daily builds. Are you making any changes to the software list?

[bvaughan527]

Hello @bvaughan527, we don't see this behavior in our daily builds. Are you making any changes to the software list?

Hi @Alexey-Ayupov , No, we are not making any changes to the software list. We are using the image as-is and following the directions here https://github.com/actions/runner-images/blob/main/docs/create-image-and-azure-resources.md. We've been following this same process for several years without issue.