Chucky is seared by acid, then gets a hose jammed into his mouth. For some reason, he can't just spit it out, and his head inflates until it explodes. The plastic from Chucky's body is melted down and poured into the mold for a new Good Guy doll head. The last shot is the freshly-formed head winking maniacally.
Continuity mistake: In one scene, Chucky and a girl are driving down a road when they get pulled over by a cop. The cop is surprised to see a "Good Guys" doll, and is shocked to see that its nose is bleeding. They do a close up of Chucky's nose, and blood is running from it. When they cut to the cops point of view, where Chucky and the girl are both in frame, the blood is gone. It doesn't reappear for the rest of that scene, even though no one wiped it away. (00:54:55)
Trivia: Even though he offered to return to work on the film, the studio forced series creator Don Mancini to submit a script for approval while several other writers also wrote their own drafts, with no guarantee his script would be used. Thankfully, Mancini's script was chosen, and he's since written every single entry in the series.TedStixon