Your fiance should go to his country's consulate in the US to apply to renew his passport. He will need to present his expired passport and possibly fill a form and comply with other requirements.
As long as you are a USA citizen and he entered legally and is otherwise admissible, once you get married, the two of you can file all the required documents to apply for the green card.
If your fiance entered with a valid visa and you get married, you can file a visa petition for him. At the same time, your fiance can file for adjustment of status. You should consult with an immigration attorney.
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