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well, there's several potential problems that may be causing this. The first would seem to be the way you're going about the smoothing, and the smoothing groups up for the car.
if you make a box primitive, and chamfer all edges, put one smoothing group on it, it's going to look quite odd, almost puffy... but very erroneous nonetheless.
The solution is, instead of chamfering the edges, you extrude the edges. Apply a base width, but don't give it any height. This not only ensures that the new edges are parallel to the faces they're created on, but also gives us a separation from each smoothing group.
The reason the box example looked bad is simply because whenever there's a polygon that's being smoothed into the next polygon, it averages in the angle of the smoothed polygon. By chamfering your edges, leaving only one, angled face there, the result will be smoothed over with the same erroneous look as the box.
I've attached a picture to better describe what I'm talking about with the smoothing groups.
The second reason may be that there's fairly wide polygons right next to the square-ish polygons, and that could possibly lead to some issues, but chances are, this issue isn't nearly the contributing factor as the previously described issue.
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