The io cache encountered an error

[kadil]

Could it be that the guest OS is writing the file faster than Virtualbox is able to to expand the hard disk file? (if filling a cache)

[oleg77]

I've got the same error on VirtualBox 3.2.8 r64453.
Host - Ubuntu 8.04, Guest - Windows 7.
The problem happend during Windows7 installation.
There are no problem with free space on the host.
I suppose it happend because I changed my HDD several days ago. I replaced Samsung HD160HJ on WDC WD3200AAJS.
Yearly I installed a lot of different VMs on my Samsung HDD w/o any problem.
There are no any errors in the system logs or smart info of the new disk. I suppose it connected with some not standard io timeouts on this disk.
Here is my VBox.log.

[ksadil]

The workaround I am using is to locate the vdi file on a secondary hard disk ( and not in the .VirtualBox directory) This has worked successfully now for months without a hitch, but I am uncomfortable that I was not able to understand what the actual problem was, or how to really fix it.

[oleg77]

The workaround I am using is to locate the vdi file on a secondary hard disk ( and not in the .VirtualBox directory) This has worked successfully now for months without a hitch, but I am uncomfortable that I was not able to understand what the actual problem was, or how to really fix it.

I have not ability to use second hard disk on this comp.
As I discribed on the old hard disk there were no such problem. I think your problem also was connected with some hard disk not compatibility.