Unable to create boundary layers for vehicle aerodynamics CFD wrapped surface

Hello

I have generated wrapped surface of a vehicle, surface meshed it and made sure that there are no intersections, non-manifold and free edges. The domain basically consists of wrapped vehicle surface and a box which encloses the vehicle. I want to volume mesh the air domain around vehicle. I am able to generate tet volume mesh.

However, i am unable to generate CFD mesh and boundary layers. I tried boundary layer mesh control but still not able to generate boundary layers. To start with, i am trying to generate just a single layer of 0.5mm thickness. I have attached the snapshot of the mesh settings.

I get following error when i try to do CFD volume mesh: Error:: Box1 Mesh failed.

This is not sufficient information and i can not figure our what is wrong and pin point the cause. 

Regards,

Subodh