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I think what saschak meant to say is "A 100% full /tmp FS can't be resized". You can increase any other filesystem that is at 100%. Therefor if you run out of space in tmp you need to make space available within this filesystem to increase it.

Do an "lsvg rootvg" to see the available space in the volume group to see how much space you can give to /tmp. Then do a "df -k /tmp" to see how much space you have left in this filesystem. You say you run the "chfs -a size=" command, what value did you set? Is it greater then the free space in the volume group?

You cant update the system from a tar file you need to extract it first then do a "smit update_all". You'll first have to fix your FS problems before you can look at this issue.