Ray G. Killian, who escaped from a prison road gang four years ago and took up a new name and a new life style before he was discovered by police, was ordered back to jail yesterday by a Fairfax County Circuit Court judge.

Judge F. Bruce Bach sentenced Killian to one year in prison on escape charges, denying Killian's plea for a suspended term. The maximum sentence for escape is five years.

"He lived on the outside for three and one-half years," said Robert S. Letnick, Killian's attorney. "He got married, he had a child, he owned a home and cars. He proved he's able to live a productive life."

But Bach interrupted the attorney's argument and shot back, "All he did was violate his parole and escape from the pen. The reason I'm only giving you one year is that it was a completely nonviolent escape," Bach told Killian, 30. "You just walked away."

Killian, who was first sentenced to jail in 1975 on burglary charges, was recently turned down for parole in those cases and must begin serving the remaining six years of those jail terms after he completes the year sentence ordered yesterday.

Killian escaped from a road gang near Camp 30 in Fairfax in 1979 while serving a combined 11-year jail term on two burglary charges. He moved to South Carolina and became Andrew Adkins with the help of another man's lost driver's license. He eventually moved to Florida, where he became a $19,000-a-year route salesman for Pepsi-Cola. He married under his new name and eventually the couple had a son and bought a house trailer.

But the couple's relationship soured, the two split up and Killian said his wife told police his true identity. The much-feared knock on the door from police investigators came last November and Killian was returned to the Fairfax jail to await trial.

In requesting the suspended jail term on the escape charge, Killian showed the judge a picture of him and his son and said, "I want to get out and be with my son before he's so old he doesn't even know who I am."

Killian's attorney argued that the South Carolina native has been treated harshly by the judicial system for two burglaries--stealing a stereo from a relative and stealing $5 from a soft-drink machine in the office of a former employer. Bach disagreed.

"You've been in one problem after another," he said. He noted that Killian had violated parole previously by walking out of a drug treatment program he was ordered to attend and that he had received a dishonorable discharge from the military.