Upgrade from 4.15 to 4.16 is failing because kubelet reports this error:

Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411346    7755 kubelet.go:308] "Adding static pod path" path="/etc/kubernetes/manifests"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411380    7755 file.go:69] "Watching path" path="/etc/kubernetes/manifests"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411406    7755 kubelet.go:319] "Adding apiserver pod source"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411426    7755 apiserver.go:42] "Waiting for node sync before watching apiserver pods"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.414274    7755 kuberuntime_manager.go:257] "Container runtime initialized" containerRuntime="cri-o" version="1.28.4-4.rhaos4.15.git92d1839.el8" apiVersion="v1"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: E0315 17:03:31.414963    7755 kuberuntime_manager.go:273] "Failed to register CRI auth plugins" err="plugin binary executable /usr/libexec/kubelet-image-credential-provider-plugins/acr-credential-provider did not exist"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: kubelet.service: Main process exited, code=exited, status=1/FAILURE
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: kubelet.service: Failed with result 'exit-code'.
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: Failed to start Kubernetes Kubelet.
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: kubelet.service: Consumed 155ms CPU time





We have seen this issue in prow job periodic-ci-openshift-openshift-tests-private-release-4.16-amd64-nightly-4.16-upgrade-from-stable-4.15-azure-ipi-workers-rhel8-f28 (a cluster with rhel workers) and in manual upgrades in IPI on GCP clusters (a cluster with coreos workers).

    

 Upgrade from 4.15.3 to 4.16.0-0.nightly-2024-03-13-061822

oc get clusterversion -o yaml
...
    history:
    - acceptedRisks: |-
        Target release version="" image="registry.build04.ci.openshift.org/ci-op-wb5fkm5k/release@sha256:da22f0582a13f19aae1792c6de2e3cc348c3ed1af67c1fbb5a9960833931341b" cannot be verified, but continuing anyway because the update was forced: unable to verify sha256:da22f0582a13f19aae1792c6de2e3cc348c3ed1af67c1fbb5a9960833931341b against keyrings: verifier-public-key-redhat
        [2024-03-15T15:33:11Z: prefix sha256-da22f0582a13f19aae1792c6de2e3cc348c3ed1af67c1fbb5a9960833931341b in config map signatures-managed: no more signatures to check, 2024-03-15T15:33:11Z: unable to retrieve signature from https://storage.googleapis.com/openshift-release/official/signatures/openshift/release/sha256=da22f0582a13f19aae1792c6de2e3cc348c3ed1af67c1fbb5a9960833931341b/signature-1: no more signatures to check, 2024-03-15T15:33:11Z: unable to retrieve signature from https://mirror.openshift.com/pub/openshift-v4/signatures/openshift/release/sha256=da22f0582a13f19aae1792c6de2e3cc348c3ed1af67c1fbb5a9960833931341b/signature-1: no more signatures to check, 2024-03-15T15:33:11Z: parallel signature store wrapping containers/image signature store under https://storage.googleapis.com/openshift-release/official/signatures/openshift/release, containers/image signature store under https://mirror.openshift.com/pub/openshift-v4/signatures/openshift/release: no more signatures to check, 2024-03-15T15:33:11Z: serial signature store wrapping ClusterVersion signatureStores unset, falling back to default stores, parallel signature store wrapping containers/image signature store under https://storage.googleapis.com/openshift-release/official/signatures/openshift/release, containers/image signature store under https://mirror.openshift.com/pub/openshift-v4/signatures/openshift/release: no more signatures to check, 2024-03-15T15:33:11Z: serial signature store wrapping config maps in openshift-config-managed with label "release.openshift.io/verification-signatures", serial signature store wrapping ClusterVersion signatureStores unset, falling back to default stores, parallel signature store wrapping containers/image signature store under https://storage.googleapis.com/openshift-release/official/signatures/openshift/release, containers/image signature store under https://mirror.openshift.com/pub/openshift-v4/signatures/openshift/release: no more signatures to check]
        Precondition "ClusterVersionRecommendedUpdate" failed because of "UnknownUpdate": RetrievedUpdates=True (), so the update from 4.15.3 to 4.16.0-0.nightly-2024-03-13-061822 is probably neither recommended nor supported.
      completionTime: null
      image: registry.build04.ci.openshift.org/ci-op-wb5fkm5k/release@sha256:da22f0582a13f19aae1792c6de2e3cc348c3ed1af67c1fbb5a9960833931341b
      startedTime: "2024-03-15T15:33:28Z"
      state: Partial
      verified: false
      version: 4.16.0-0.nightly-2024-03-13-061822
    - completionTime: "2024-03-15T13:33:08Z"
      image: registry.build04.ci.openshift.org/ci-op-wb5fkm5k/release@sha256:8e8c6c2645553e6df8eb7985d8cb322f333a4152453e2aa85fff24ac5e0755b0
      startedTime: "2024-03-15T13:02:04Z"
      state: Completed
      verified: false
      version: 4.15.3


    

Always
    

    1. Upgrade from 4.15 to 4.16 using prow job periodic-ci-openshift-openshift-tests-private-release-4.16-amd64-nightly-4.16-upgrade-from-stable-4.15-azure-ipi-workers-rhel8-f28 or an IPI on GCP cluster.
    
    

Worker nodes do not join the cluster when they are rebooted:

sh-4.4$ oc get mcp
NAME     CONFIG                                             UPDATED   UPDATING   DEGRADED   MACHINECOUNT   READYMACHINECOUNT   UPDATEDMACHINECOUNT   DEGRADEDMACHINECOUNT   AGE
master   rendered-master-b566c3af4e215e2a77e6f9d9e5a988de   True      False      False      3              3                   3                     0                      3h59m
worker   rendered-worker-21862c92d0f14a4842f6093f65571bd1   False     True       False      3              0                   0                     0                      3h59m

sh-4.4$ oc get nodes
NAME                                  STATUS                        ROLES                  AGE     VERSION
ci-op-wb5fkm5k-e450c-s6m96-master-0   Ready                         control-plane,master   4h5m    v1.29.2+a0beecc
ci-op-wb5fkm5k-e450c-s6m96-master-1   Ready                         control-plane,master   4h6m    v1.29.2+a0beecc
ci-op-wb5fkm5k-e450c-s6m96-master-2   Ready                         control-plane,master   4h6m    v1.29.2+a0beecc
ci-op-wb5fkm5k-e450c-s6m96-rhel-1     NotReady,SchedulingDisabled   worker                 3h17m   v1.28.7+6e2789b
ci-op-wb5fkm5k-e450c-s6m96-rhel-2     Ready                         worker                 3h17m   v1.28.7+6e2789b
ci-op-wb5fkm5k-e450c-s6m96-rhel-3     Ready                         worker                 3h17m   v1.28.7+6e2789b

In the NotReady node we can see this error in kubelet

Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411346    7755 kubelet.go:308] "Adding static pod path" path="/etc/kubernetes/manifests"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411380    7755 file.go:69] "Watching path" path="/etc/kubernetes/manifests"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411406    7755 kubelet.go:319] "Adding apiserver pod source"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.411426    7755 apiserver.go:42] "Waiting for node sync before watching apiserver pods"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: I0315 17:03:31.414274    7755 kuberuntime_manager.go:257] "Container runtime initialized" containerRuntime="cri-o" version="1.28.4-4.rhaos4.15.git92d1839.el8" apiVersion="v1"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 kubenswrapper[7755]: E0315 17:03:31.414963    7755 kuberuntime_manager.go:273] "Failed to register CRI auth plugins" err="plugin binary executable /usr/libexec/kubelet-image-credential-provider-plugins/acr-credential-provider did not exist"
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: kubelet.service: Main process exited, code=exited, status=1/FAILURE
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: kubelet.service: Failed with result 'exit-code'.
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: Failed to start Kubernetes Kubelet.
Mar 15 17:03:31 ci-op-wb5fkm5k-e450c-s6m96-rhel-1 systemd[1]: kubelet.service: Consumed 155ms CPU time

    

The upgrade should be executed without failures

    

In the first comment you can find the must-gather file and the journal.logs