The character had been killed episodes before and appeared totally unexpectedly in the episode called Unearthed. As the Wikipedia notes:

Though his character Charlie Francis had been killed off earlier in the second season, former series regular Kirk Acevedo appeared in the episode, sparking confusion among some viewers.

Has this ever been properly explained?

  • That explanation doesn't really make sense considering the plot of the "unearthed" episode follows events that happened in S2E1. It sounds like they took some junk footage they discarded earlier and just slammed it into this episode with total disregard for how foolish it looked. – user11887 Jan 11 '13 at 18:23
  • @user11887 What parts of the plot follow S2E1? – user1027 Jan 11 '13 at 18:47
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    @Keen None that I recall. He may be referring to the press release that Fox added, which hinted that the episode may be set in an alternate universe. That, however, is not part of the episode and is just Fox being stupid. – Izkata Jan 12 '13 at 0:22
  • God... finally some closure :P – Priidu Neemre Jun 29 '15 at 16:34
  • God. Thats rubbish. – ʞɹᴉʞ ǝʌɐp Jul 15 '17 at 19:10

Basically, it was an episode they made during the first season, but didn't air. Fox decided to air it during the second season.

This was explained during its original airing. The Fox promos for that episode explained it as a 'lost 1st season episode'. That's why Charlie's there, and there's no attention drawn to his presence, as he was always around during season 1.

Also, in this scan of the blu-ray booklet, you could see that the Unearthed episode is within the special feature of the disk 4. So the episode number 11 is "Johari Window".

blu-ray booklet

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    Go Fox! </sarcasm> – Izkata Nov 24 '11 at 19:51
  • Stupidity is always good thing. I mean they did not air it but who cares throw it in the second seasond. It all makes sense – John Demetriou Oct 24 '14 at 13:37
  • When watching the series on (Dutch) Netflix, it's positioned between seasons 1 and 2. Which did make some sense, regarding people coming back from apparent death and screaming gibberish. But it probably would have been better before the final episode of the first season. – SQB Nov 13 '14 at 20:41
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    Explains Agent Farnsworth's hair as well. Thank you for explaining this, was going a bit nuts. – troglobit May 23 '20 at 19:34

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