Here's what I wrote for the OOTP wiki:
Updating In-game Facegens After Adding New Files to the fg_files Folder
OOTP creates a facegen for a player the first time it loads the player (and so has need to generate one). Thereafter it is saved in a cache file under the league save folder. To refresh a particular player, go to the Player Editor and halfway down the lefthand side, there will be an option for "Picture functions", which, when clicked, provides a drop-down menu. Select "auto-reload picture" and the new file should load.
If you wish to clear all the cached facegens in a particular save to force the game to recheck all the files in the fg_files folder, go to the saved games folder (go to Settings from the Start Screen, at the pop-up pick troubleshooting, open saved games folder). Once you open the .lg folder, go to news, html, images, profile pictures. You will see the cached facegen .png files there for that save. Select all and then unselect the “default_profile_picture” (to keep it) and delete those cached facegen .png files. Thereafter, the game will create new facegens as if it were its first time visiting that player's profile.
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Clearing the cache is also important to when switching midstream from facegens to photos. By doing the deletion I mention in that last paragraph above, you will have "cleared" the cache and, if you are set-up to load photos properly, the next time you visit the player, it will not find a facegen in the cache and it will look anew for something to load for that player. Again, if set-up for photos properly, that new something is a photo.
Hope that works for you.
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