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Tatiana(ACME Russia detective) makes a return.
Lee Jordan, from Boyhood's End Parts 1 & 2, returns in this episode (coincidentally, also a two-parter).
After doing the math of the fire at Carmen's house, which happened 30 years ago, and the orphanage takes her in at age two, we find Carmen's age to be around 32.
According to Ivy, they processed Jordan Lee last year. Meaning that between the past two seasons, only one year has passed.
The Chief pulls his robot body out of storage and transfers his AI back into it to help out Zack and Ivy... and finds it's still as useless as the day he was brought online.
While dressed as Carmen Sandiego, Ivy's legs are exposed (and exact duplicates of Carmen's distinctively shapely "gams"), yet as she quickly discards the costume, they're fully sheathed in her usual pants. Now, unless she tied them about her waist under that trenchcoat and stopped to slip them on as Carmen revealed herself...