Hi, and welcome to the forums!

Having been in immigration trouble here in France, let me tell you that you do NOT want to fool with the US immigration people!

>>1. Will my fiance visa be revoked due him being here illegaly?<<

Are you a US citizen? Do you already have a fiancé visa for the UK? Generally, his illegal status in the US shouldn't affect your visa status in the UK, but his being illegal certainly won't help, either. It could complicate your return to the UK.

>>2. Is there any other way that I can work and live in the UK with out getting married { I know to apply for worker visa, or student visa however I dont go to school, and any visa must be applied for in your own country so I would have to leave and come back}<<

Check the UK embassy website in the US (New York City or Washington DC) for details on the types of visas they offer, but generally you are going to need to find a job in the UK to get a work visa. Or, get accepted to a university or other programme in the UK to get a student visa. Yes, you probably would have to leave the UK to apply for a different sort of visa, and it might be taken the wrong way if you had already arrived in the UK on the fiancé visa, then turn around and say, "oh, we don't want to get married yet" and apply for a different sort of visa. At the least, you'll be suspected of having lied on the fiancé application. If you are going to change the type of visa you go over on, do it before you go.

>>3. If I apply for a workers Visa, can I still get married later on, and apply for the visa that will allow me to become a british citizen?<<

No problem there (other than the issue of whether or not you "changed your mind" above) - but you have to find a job in the UK first. And that's not easy from outside the country.

>>4. What kinda of trouble are we looking at with him being here illegaly at the airport?<<

Arrest is the most likely outcome, though if he's on his way out of the country when he's caught, they might just let him go. (Cheaper than deporting him.) HOWEVER - if he is caught overstaying his US visa, he can be denied entry to the US in the future, even for a holiday or to visit your family.

>>5. Will he have to go ahead of me, and establish residency again? We do not want to part ov course.<<

His best move is to get the heck out of the US within the time period of his visa - even if he just goes up to Canada for a month or two. If he re-enters the US too soon after leaving, even on a tourist visa or the visa waiver program, there is a real danger that his passport/name will be flagged the next time he tries to enter the US. And that could be trouble.

It wouldn't hurt for him to go back to the UK so that he can establish residence there when you arrive. On a fiancé visa, he may have to show that he can support you without your having to take public assistance. It would be far better for him to be back over there with a job when you arrive.

Sorry to be the bearer of bad news, but do what you can to avoid immigration trouble down the line. It's not fun and it gets very expensive to fix a situation you could have avoided in the first place!
Cheers,
Bev