I have a problem with restoring a config file into a newly-rebuilt
machine (Alix 2d3) with v1.2.3, that causes the GUI to regularly complain
"XML error: no pfsense object found!"
and in general to require a full reboot before any GUI changes can be
applied, even though /cf/conf/config.xml is correctly changed.

Full description:

At one site I have a PC Engines Alix 2D3 machine, running a full install
of pfSense 1.2.3 on a 1GB CF card. We have 3 physical interfaces and a
wireless card acting as an AP.

Recently the machine was rebooted, and failed to come up properly.
Investigation showed that /usr/sbin was completely missing (also
/usr/X11R6 and /usr/share). It's possible that filesystem corruption had
caused this, but by the time I got to it, the fs was clean and fsck
found nothing unusual.

We have a backup of the config, produced by grabbing the output from
diag_backup.php every day.

I used VirtualBox (PUEL 4.08 on Ubuntu 10.10 64) to install a new copy
of pfSense onto a new CF card, booting from the 1.2.3 LiveCD and
connecting the CF card to VBox with a passthrough vmdk file. Although
there were a lot of odd issues whereby most of the CF cards I had
available simply did not work when accessed with FreeBSD (throwing read
and write errors constantly; but working just fine when accessed by
other OSs) the original CF card and one new one seemed to work perfectly.

I booted up the Alix 2d3 with the new clean pfSense 1.2.3, assigned a PC
into 192.168.1/24, and logged in to the web GUI. I then used the restore
page to re-present the old config file we had. After reboot, everything
looked good - the right IPs and interfaces were assigned, the AP started
up normally.

After we put the machine back into service, and confirmed access was
fine, it was time to make a few changes to things like aliases. This is
where the current problem lies ...

As an example, I have an alias that needed updating; one IP address
needed to be added. Going to Firewall/Aliases displayed the current list
of aliases correctly; selecting "[e]" took me to the correct Edit
screen. I made my change, and selected "Save". The response I get was a
blank page with the error message "XML error: no pfsense object found!"

> http://10.23.1.2/firewall_aliases_edit.php says
> <html><head></head><body>XML error: no pfsense object found!
> </body></html>

When I cleaned the URL to get back to the main page, and re-selected
Firewall/Aliases, I saw the "Apply Changes" button -- but clicking
through to the edit page showed the old content, not my changes.

Pressing "Apply Changes" seemed to work, and the filter reload reported
no problems. Returning to Firewall/Aliases/Edit showed the old values.

At this point, the /cf/conf/config.xml file contained the correct
changes, but the GUI didn't reflect them, and when I downloaded the
configuration from the GUI, I got the old values.

Next, I rebooted the firewall, and discovered that the new config was
correctly applied.

I have tried to repeat this in a VirtualBox VM, but it does not fail --
applying the old configuration simply leads to the machine starting up
happily with the new configuration (just complaining about the interface
mismatches ... the real hardware has vr[012]|ath0 and the virtual
machine has em[0123] instead). Edit to the new configuration are
accepted without error, and apply properly.

I cannot do very much experimentation with the machine as it is
currently in production use, but I need to find a way to fix the problem
of making changes.

I would appreciate advice on further debugging, and on ways to restore
normal function to this machine :-) If I had spare working CF cards, I
would consider repeating all this and upgrading to 2.0RC1.

-jim

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